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1994-2002

1. WHAT TYPE OF GASOLINE TO USE A WARNING All carbureted and standard EFI engines run on unlead Gasoline vapors are highly flammable and ed fuel of 89 Octane R M 2 or higher The LS1 explosive requires 93 octane or higher Fuels must meet the speci fication ASTM D4814 in the US and CGSB 3 5 92 in Never SMOKE WINE TERENNg Keep Sparks Canada These fuels need no additives and flames away from fuel Only refuel in well ventilated area Never overfill fuel tank Stop engine before fueling Swallowing or inhaling gasoline or fumes is dangerous Seek medical attention Gasoline spills on your skin should be washed immediately with soap and water INDM A021 If gasoline spills on clothing change cloth ing immediately Avoid spilling gasoline Clean spills with dry cloth and dispose properly Figure 5 1 Filling Fuel Tank Indmar Marine Engines 5 1 5 2 INDM A022 Figure 5 2 Inspecting Fuel Lines CAUTION 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 fuel every two weeks Today s fuels are more susceptible to degradation and the use of a quality stabilizer will help ensure fewer problems for the occasional boater If your boat has not been used for more than 30 days with fuel in the tank even stabilized fuel the engine may run poo
2. IMPORTANT SAFETY INFORMATION Throughout this manual specific precautions and sym bols identify safety related information CAUTION Indicates the presence of a hazard which The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WILL or CAN cause MINOR or MODERATE personal injury or property damage AN DANGER NOTICE Indicates the presence of a hazard which Indicates installation operation or maintenance infor WILL cause SEVERE injury death or sub mation which is important but not hazard related stantial property damage The precautions listed in this manual and on the engine or boat are not all inclusive If a procedure method tool or part is not specifically recommended you must satisfy A WARNING yourself that it is safe for you and others and that the engine or boat will not be damaged or made unsafe as a result of your decision Indicates the presence of a hazard which CAN cause SEVERE injury death or substan tial property damage Indmar Marine Engines i Indmar Marine Engines WELCOME Dear Indmar Marine Engine Owner Congratulations on selecting the finest marine inboard power available for your boat Team Indmar welcomes you to our family of owners Indmar proudly stands behind our products and is the first inboard manufacturer to offer a 3 year limited warranty We want you to know that your engine was manufactured to surpass industry standards Before leav i
3. engine AN DANGER 1 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 of replacement electrical ignition or fuel sys tem components which do not comply to these rules and regulations could result in a fire or explosion hazard and should not be used Indmar Marine Engines Your safety depends on your use of marine parts When servicing the electrical ignition and fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignition component could permit sparks to ignite fuel vapors from fuel system leaks if they existed Since marine engines are expected to operate at near full throttle for most of their life and to operate in fresh and salt water environments many special parts and fas teners are used which are quite different from standard automotive parts Many parts are made from special cor rosion resistant materials while other moving parts are heavy duty for continuous high RPM duty If you perform minor service procedures make sure to use genuine Indmar parts for marine use 6 1 AN WARNING CAUTION You can be injured if you try to work on your Never operate engine without adequate water marine engine without knowing enough supply to the raw water pump Failure to about your engine properly cool engine will cause severe Be
4. 1 Remove the dipstick and wipe with a clean towel 2 Insert the dipstick completely do not screw in threaded dipstick to check fluid Remove the dipstick and read fluid level Indmar Marine Engines 3 Return dipstick after level check Make sure it is secured in place 4 If level is below ADD mark add the proper fluid until it reaches the full mark Add fluid through same tube as you removed the transmission dipstick INDM A031 Figure 6 9 Walters V Drive Dipstick Location 6 11 TRANSMISSION MODEL RATIO CAPACITY FLUID TYPE ZF Hurth In Line 450D 1 1 1 7 gt 1 6L Pennzoil Dexron Il Ill or MERCON ZF Hurth In Line 450A 1 5 1 2 12 qt 2L Pennzoil Dexron Il Ill or MERCON ZF Hurth In Line 630A 1 5 1 4 2 qt 4L Pennzoil Dexron Il Ill or MERCON ZF Hurth V Drive 630V 4 2 qt 4L Pennzoil Dexron Il III or MERCON Walters V Drive RV 26D 71V 0 5 qt 0 5L Pennzoil SAE 30 Motor Oil CAUTION Do not overfill the transmission Overfilling can damage the transmission Damage to your 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 circuit breaker 1 Figure 6 10 to protect the engine electrical system and components from overload If the engine will not crank with the battery switch in the ON position locate the red breaker reset button labeled 50 at the back of the en
5. fluid will cause the seals to leak and eventually lead to overheat ing while if there is too little fluid overheating will result HIGH If the engine uses the Walters V Drive it is equipped with a ZF Hurth in line transmission for shifting Be aware that the Walters V Drive uses motor oil for lubrication while the ZF Hurth transmission uses Automatic Transmission Fluid The Walters V Drive also has a low oil pressure sensor and a dashboard mounted light If low oil pressure is sensed this lamp will light indi cating the problem Shut down the engine and check the transmission fluid level Refer to Chapter 6 Check Transmission Light for more information LOW INDM A039 Figure 6 8 Walters V Drive Dipstick Indmar Marine Engines If transmission service is required note the Serial Number of the transmission stamped onto the ID plate on the top of the transmission housing It is good practice to note the serial number noted and keep it with other owner 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 on the top of the transmission Dipsticks may be marked ADD and FULL or H and L high and low maintain fluid level between the two marks CAUTION Check level immediately after turning engine off Transmission fluid may be hot Be careful not to burn yourself
6. 50 hours or annually whichever comes first To maximize engine life change the oil filter at every oil change Figure 6 4 Oil Filter Indmar recommends all engine maintenance procedures be performed by your dealer including oil changes If you must perform the oil change yourself operate the engine to full operating temperature 6 5 Oil Additives CAUTION Do not use oil additives Indmar engines do not need oil additives Use of recommended oil along with regular oil and oil filter changes will protect your engine adequately 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 the hull opening outside of hull 2 Remove QuickDrain hose cap and let oil flow into used oil container 3 When all oil has drained replace cap and return QuickDrain to storage position Replace the hull or garboard drain plug 4 Position a suitable container under the oil filter Unscrew and remove the oil filter ensure that filter seal is removed with oil filter Wipe up any spilled oil in the bilge and dispose of properly 5 Fill a new Pennzoil Marine oil filter about 1 2 full with Disposing Used engine oil contains dangerous chemicals and is considered a hazardous waste Do not allow used oil to remain on your skin for any length of time Make certain to drain all free flowing oil from the filter prior to disposal R
7. better and require fewer repairs over its lifetime Your new Indmar engine does not require an elaborate break in procedure just a little care and com mon sense for the first 7 hours 1 3 Break in Tips Always let engine warm up to normal operating tem perature before accelerating EFl engines including the LS1 are programmed with a phased warm up to ensure that the engine is warm before full RPM is possible refer to Table 1 1 Table 1 1 EFI Phased Warm Up TEMPERATURE TIME RPM LIMIT 103 F 40 C or less 3000 RPM 10seconds 4200 RPM 104 to 139 F 41 to 59 C Full RPM 140 60 C and higher 10 seconds e Avoid fast accelerations and don t carry or pull a heavy load during this period Check engine and transmission fluid levels frequently During the first 50 to 100 hours an engine can use more oil than usual Maintain oil at proper levels at all times but do not overfill e Vary your boat speed during break in Do not run at the same speed very long Observe gauge readings and check for loose mount ings fittings nuts bolts and clamps Report abnormal operation noises or vibrations to your dealer 1 4 Break in Steps 1 For the first hour do not exceed 2000 RPM vary RPM continuously 2 For the second hour do not exceed 3000 RPM 3 For the next five hours do not exceed 4000 RPM After the first ten hours of operation take your boat to the dealer for its
8. 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 Indmar Marine Engines C 1 e Failure of any parts caused by lack of cooling water which results from starting motor out of water or foreign materials blocking intake passages e Air freight next day or second day air or any special delivery fees unless authorized by Indmar prior to ordering of parts e 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 Warranty Indmar Products Co Inc 5400 Old Millington Road Millington Tennessee 38053 Indmar warrants marine propulsion engines sold by it the Product NOTICE Indmar reserves the right to retrieve run time run condition data from
9. 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 or ii 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 INDMAR DOES 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 LIABILITY WITH 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 THE STATED EXPRESS WARRANTY IS IN LIEU OF ALL LIABILITIES OR OBLIGATIONS OD INDMAR FOR DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE DEVELOPMENT DELIVERY USE OR PERFORMANCE OF THE PRODUCT IN ANY EVENT 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 the product This warranty gives you specific legal rights and you may also have o
10. equipped with a Check Engine light which 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 Power reduction limits the engine speed to a safe maneuver ing speed of about 1600 RPM This mode is intended to allow the driver to get out of harms way and to reach safe harbor for engine service CHECK ENGINE INDM A018 Figure 4 5 Check Engine Light Indmar Marine Engines The Check Engine light may activate if any of the follow ing conditions are noted e Low Oil Pressure High Coolant Temperature e High Transmission Oil Temperature Any of these conditions will also put the engine into Power Reduction mode If the Check Engine light should go on or if the engine enters the Power Reduction mode you should have your dealer check the engine as soon as possible CAUTION Schedule engine service at once when this light is illuminated Failure to have your engine serviced when a check engine light signal is given may cause damage to your engine or your emissions system The ECM also provides for a tapered engine RPM reduction if engine coolant temperature approaches the high operating limit If the coolant temperature exceeds 176 F 80 C the engine RPM is gradually reduced until a safe temperature is reached If the engine RPM should decrease due to
11. first engine and transmission oil and filter change and engine checkup Your Indmar dealer is best equipped to check the engine immediately after break in After the break in procedure is over your boat may be operated continuously at any speed Be sure to check the wide open throttle operating range refer to Chapter 4 Selecting A Propeller CAUTION Do not exceed maximum RPM recommended for your engine Exceeding the maximum RPM may result in damage to the engine Indmar Marine Engines Chapter 2 GENERAL OPERATION AND WARNINGS Operating a boat is a safe and enjoyable experience AN WARNING Before starting engine operate bilge blower at least 4 minutes and raise engine cover to ventilate fumes Inspect engine and compart Indmar marine engines use gasoline for fuel The area under the engine and around the gasoline tank and sup ply lines is not open to outside air Ventilation around these areas must be provided by your bilge blower sys tem and air vents located around the boat We recom ment for any fluid or fuel leaks Failure to do mend taking time out to carefully inspect your boat at so can possibly result in fire and or explo least once a day for gasoline fumes oil leaks and areas sion resulting in death or serious injury to where wiring may be worn or damaged you and your passengers When refueling make sure to open the motor box and A DANGER run the blower during and after the re fueling operati
12. 4 1 Table 4 1 EFI Phased Warm Up TEMPERATURE TIME 103 F 40 C or less RPM LIMIT 3000 RPM 4200 RPM Full RPM 104 to 139 F 41 to 59 C 140 60 C and higher 10 seconds 10 seconds INDM A015 Figure 4 1 Temperature Gauge 4 Monitor your gauges and warning lights frequently to ensure that engine temperatures and pressures are within the proper ranges INDM A014 Figure 4 2 Oil Pressure Gauge 4 2 OPERATING THE CONTROLS Be sure to refer to the boat owner s manual for additional information Should there be any difference between the information presented in this manual and the boat owner s manual the boat owner s manual should take precedence The shift throttle control is important to daily operation Have your dealer check it regularly for proper adjustment and lubrication NOTICE 3 Avoid using the throttle lever during the start ing sequence Your electronic engine controls AXI should not need any throttle movement while starting Your engine has a safety feature that allows the engine to crank only in the neutral position If during the starting process your engine will not turn over make sure that the shift throttle control is in the NEUTRAL position and try again Indmar Marine Engines Most boats have an engine safe ty switch 1 Figure 4 3 that can be activated if the driver moves from the helm position If you experience a no sta
13. Check electrical connections and ensure connectors are tight Check wiring for signs of wear and abrasion 14 Verify throttle shift control is functional and properly adjusted 15 Verify steering controls are functional and properly adjusted 16 Verify battery connections are clean and securely fastened INDM A009 Figure 2 3 Engine Oil Filter 7 Check transmission fluid level Check V Drive fluid level if equipped 8 If your engine is equipped with a fresh water cooling system 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 Figure 2 4 Battery Connections 12 Verify engine mounts are tight INDM A010 Indmar Marine Engines 2 3 Indmar Marine Engines Chapter 3 ENGINE STARTING PROCEDURES When refueling make sure to open the motor box and A DANGER run the blower during and after the re fueling operation Failure to do so may result in fire or explosion and may cause death or serious injury Explosive gasoline and battery fumes may accumulate in your engine compartment Failure to properly ventilate fumes with the bilge blower may result in explosive atmos phere resulting in death or serious injury to you and your passengers AN WARNING Never remove or modify any components of the engine s fuel system Tampering w
14. Engines CAUTION Running your engine with your boat out of water will damage or ruin your engine Damage to your engine caused by overheat ing is not covered by your warranty CAUTION Running the engine during the RPM reduc tion phase may cause severe damage to your engine e Monitor the temperature and oil gauges continuously e lf the temperature rises past 200 F 93 C or your oil pressure drops below 4 psi 41 kPa STOP THE ENGINE 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 from the engine outside of the boat These hoses carry water that has been used to cool the engine This water keeps the hoses cool and prevents them from melting Indmar Marine Engines AN DANGER 1 Carbon monoxide gas CO is colorless odorless and extremely dangerous All engines and fuel burning appliances produce CO as exhaust Direct and prolonged expo sure to CO will cause BRAIN DAMAGE or DEATH Signs of exposure to CO include nausea dizziness and drowsiness Ensure adequate ventilation to prevent accumulation of CO in the boat Monitor the engine temperature gauge frequently If your engine overheats carefully inspect the exhaust hoses for damage Damaged hoses can allow carbon monoxide gas to enter your boat SELECTING A PROPELLER For best engine performance and lo
15. NS Spark plugs fouled or cracked Spark plug or distributor wires loose or shorted Plugged positive crankcase ventilation system Engine in need of tune up Engine needs to be adjusted for high altitude operations Engine needs to be adjusted for temperature extremes Carburetor out of adjustment Carbureted Engines Only Hard Start Hot D ARON gt m OPNDANRON gt Flooding condition Loose electrical ground at engine Closed choke Carbureted Engines Only Plugged flame arrestor Fouled spark plugs Loose coil or ignition wires Battery cables loose or corroded Weak or discharged battery Vapor lock ngine Won t Crank Weak or discharged battery loose or corroded battery cables Defective Neutral Safety Switch or adjustment needed Defective starter motor Ignition switch problems Hydrostatic lockup remove spark plugs to look for water or gasoline in cylinders Seized engine turn crank pulley with socket and ratchet Indmar Marine Engines Appendix A MAINTENANCE COMPONENTS AND FLUIDS Engine Oil 15W 40 Pennzoil Marine API Service SJ CG4 Racing Oil Engine Oil Filter All 5 7 Liter except LS1 Pennzoil PZ3 LS1 NAPA Gold 1042 8 1 Liter AC PF454 Engine Coolant for closed systems Sierra brand propylene glycol ZF Hurth Transmission Fluid amp V Drive Pennzoil Type A Dexron Il Ill or Dexron Mercon Walters V Drive Oil SAE 30 Pennzoil Motor Oil Engine Fuel f
16. an engines Electronic Control Module prior to granting warranty 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 Or c 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 Or b 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 C 2 Indmar Marine Engines 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 the boat is sold or traded prior to the end of the warranty period the remainder of t
17. ay The Federal Boat Safety Act of 1971 requires registra tions of marine products sold in the United States be maintained by the manufacturer and dealers of those products Your dealer should have completed your war ranty registration card to comply with federal regulations This registration enables us to contact you if it should become necessary to change or improve your product The engine serial number is stamped into the block and should also be on your warranty card Always retain a copy of the serial number for your personal records If your dealer did not fill out the card and give you a copy contact your dealer vi Warranty registration must be received within 10 days after date of purchase by the first owner If your engine is not registered all warranties may be void To obtain enjoyment from your boat follow recommenda tions described in this manual The knowledge you gain through careful review will help you experience lasting satisfaction Further information regarding the care operation required equipment or specifications for your boat can be obtained from your local US Coast Guard Auxiliary US Power Squadron state boating authorities or the American 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 its components unreasonably dangerous will void all war ranties and Indmar will not
18. be liable for the resulting damages or injuries Indmar Marine Engines Chapter 1 FIRST TIME OPERATION AND BREAK IN The following checks assumes your dealer has performed the pre delivery service and inspection Complete the following pre start check list before starting your engine for the first time If you have questions about any of these procedures see your Indmar dealer for assistance FIRST TIME OPERATION 1 Check the boat hull and or garboard drain plug Make sure they are installed and secure Check the boat owner s manual for additional pre operation checks 2 Make sure all engine drain plugs are installed Refer to Chapter 7 Storage and Winter Layup There are several drain locations Block Two drain plugs on each side 5 7 Liter EFI engines have an Engine Knock Sensor 1 Figure 1 2 installed in one drain hole NOTICE On the 8 1 Liter engine removing the knock sensor does NOT drain the block Remove the plugs from the brass fillings on both sides of the engine to drain water from the block Indmar Marine Engines Exhaust The drain hose must be connected Transmission The transmission oil cooler has one drain plug In addition the Walters V Drive if equipped has two drain plugs Fresh Water Cooling System If equipped the heat exchanger has four drain plugs two for raw water and two for coolant Refer to Chapter 7 Storage and Winter Lay up IND A005 Figure 1 2 Anti Knock Sen
19. by improper win terization storage is not covered by product warranty To properly winterize your engine you MUST be able to bring the engine up to operating temperature To accom plish this your boat must be in the water or be attached to a water supply using a hose and suitable adapter that will allow an uninterrupted supply of water to the engine NOTICE This procedure covers only the power package portion of your boat Consult your boat owner s manual or boat manufacturer for specific boat winterizing instruc tions GENERAL PREPARATION Before 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 e 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 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 e Sierra Brand Anti Freeze As required for Fresh Water Cooled Engines Only 1 can Pennzoil Marine Z M Corrosion Protectant and Fuel System Treatment If the boat is to be placed in storage with fuel in the tank s that does not contain alcohol fil
20. d be in the neutral position with the neutral detent button on the shift control box pulled out 4 After the engine starts release the key The engine will gradually slow from a fast idle to normal NONEAGIE idle If engine is cold it Figure 3 2 Start will operate at a slightly Position higher idle speed until warm up is complete Make sure that when you do shift into gear that you are at idle speed less than 1100 RPM Let engine warm up to normal operating temperature before accelerating EFl engines includ ing the LS1 are programmed with a phased warm up to ensure that the engine is warm before full RPM is possible refer to Table 3 1 Indmar Marine Engines Table 3 1 EFI Phased Warm Up TEMPERATURE TIME RPM LIMIT 3000 RPM 103 40 C or less 104 to 139 F 41 to 59 C 10seconds 4200 RPM 140 60 C and higher 10seconds Full RPM INDM A013 Figure 3 3 Tachometer CAUTION Once the engine has started immediately check the oil pressure Monitor the oil pres sure and engine temperature closely for the first 10 minutes of operation Indmar Marine Engines IF ENGINE DOES NOT START CAUTION Do not operate starter motor for more than 15 seconds without a 2 two minute cool down period Excessively long cranking times will permanently damage the starter motor and drain the battery Damage from overheating the starter motor is not covered by the warranty H
21. damage If the WOT RPM is lower than the minimum RPM in your engine 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 Lugging places tremendous loads on the pistons crankshaft and bearings and can cause detonation piston seizure and other engine damage Elevation and weather also have a very noticeable effect on the wide open throttle power of an engine Since air containing oxygen gets thinner as elevation increases the engine begins to starve for air Humidity barometric pressure and temperature have a noticeable effect on the density of air since heat and humidity thin the air This phenomenon can become particularly apparent when an engine is propped out on a cool dry day in spring and later on a hot humid day in summer does not have the same performance Although some per formance can be regained by dropping to a lower pitch propeller the basic condition still exists The propeller is too large in diameter for the reduced power output An experienced marine dealer can determine how much diameter 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 The dealer is best equipped to help with the selection of the correct propeller for your application s Indmar Marine Engines Chapter 5 FUEL
22. eased boat a copy of the lease contract showing the length of the lease must also be included No warranty claims will be honored without prior receipt of the Indmar Warranty Registration Card For warranty claims to be asserted hereunder the Product or defective part thereof together with a written notice of itemized defects must be returned to the retailer from whom the product was purchased or to any other convenient Indmar dealer To obtain the location of an authorized Indmar dealer or service center in 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 be returned to Indmar with freight and insurance charges prepaid All insurance and freight charges and return charges by Indmar of the Product or its substitute to the retail purchaser shall be paid by the purchaser Expenses for labor incurred by Indmar in the repair of any warranted product shall be paid by the retail purchaser or lessor to the extent that such expenses for labor exceed the specified service rates of Indmar in effect at the date of purchase by Indmar A schedule of service rates of Indmar may 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 Indmar Marine Engines C 3
23. ecycle used oil by taking it to a collection center If you have a problem disposing of used oil ask your Indmar dealer or service station for the name of a local oil recy cling center for proper disposal clean engine oil Lightly lubricate the oil filter gasket and spin on the filter until the gasket makes contact A WARNING Hand tighten filter 1 4 to 1 2 turn after contact Prolonged and repeated contact with used 6 Add the new oil through the cap located on the engine oil may cause skin cancer engine valve cover Fill only to the FULL mark of dip stick 7 After initial start up always carefully inspect oil drain plug and oil filter gasket area for leaks Avoid direct skin contact with used oil If skin contact is made wash thoroughly with soap or hand cleaner as soon as possible 8 Stop the engine and re check oil level Add if neces Keep used engine oil out of reach of children sary Used engine oil is a hazardous material Dispose of properly 6 6 Indmar Marine Engines ENGINE FLAME ARRESTOR Your engine is equipped with a U S Coast Guard approved flame arrestor Its purpose is to contain any backfire that may occur during the operation of your engine Because an inboard engine is completely enclosed an uncontained backfire can be extremely dangerous INDM A027 Figure 6 5 Flame Arrestor Periodically inspect flame arrestor to prevent clogging by dirt or corrosion There are two types of
24. er bendix every month or 50 hours of operation Your starter has been sprayed with lubrica tion internally to extend its longevity SHIFT AND THROTTLE CABLES Spray exposed throttle cable and transmission cable ends with Pennzoil Marine Z M Corrosion Protectant and Lubricant or Pennzoil Premium Plus multipurpose grease Work the cable back and forth then spray to completely lubricate In highly corrosive locations a com plete cable lubrication system may be purchased through your Indmar dealer 6 13 6 14 Indmar Marine Engines Chapter 7 STORAGE AND WINTER LAY UP Storage or winter lay up requires preparation to prevent damage to the power package While preparing the power package for winter lay up annual maintenance tasks should also be performed Without proper preparation storage over a long period of time may cause internal engine and transmission parts to rust due to lack of lubrication Also if the boat is stored where the temperature falls below freezing any water not drained from the engine may freeze resulting in severe damage Damage that is the result of improper storage is not covered under terms of Indmar s limited warranty Indmar Marine Engines AN WARNING Because of the complexity of preparing your engine for winter storage and the danger of catastrophic engine damage from freezing water in the engine it is recommended that you have your dealer perform winterization procedures Damage due to
25. flame arrestors used in Indmar engines metal and paper Metal Type The metal flame arrestor is cleaned using a mild part washing solvent Using solvent clean the flame arrestor Indmar Marine Engines thoroughly and blow dry The metal flame arrestor must dry completely before it is returned to the engine Paper Type This type of flame arrestor should be blown clean from the inside monthly and replaced annually Use only gen uine Indmar replacement parts to ensure proper fit and protection against fire and explosion When cleaning or replacing the flame arrestor clean the breather hose and replace the PCV valve at the same time AN WARNING Do not remove the flame arrester at any time when the engine is being started or run as it may result in fire explosion and death or serious personal injury ENGINE COOLING AN WARNING Running engine without adequate cooling can cause engine to overheat and may result in fire explosion death and or personal serious injury AN WARNING Closed cooled engines are shipped from the Indmar factory filled with a 50 50 mix of Sierra brand antifreeze and water This mix ture provides freeze protection down to 26 F 32 C If the temperature in your area is expected to go below this level of protection see your Indmar dealer to have the antifreeze mixture adjusted for your needs CAUTION Running your engine with your boat out of water will damage or ruin your engi
26. g 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 B 2 Indmar Marine Engines Appendix C LIMITED WARRANTY What Is Covered by Warranty Any part s that fails as the result of defects in material and workmanship will be replaced at no charge to the customer under the terms 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
27. gine Firmly push the red button until the breaker resets an audible click will be heard Start the engine 6 12 INDM A029 Figure 6 10 Breaker Reset Button Indmar Marine Engines If the breaker trips again there is a problem with the electrical system Take your boat immediately to your Indmar dealer for repair NOTICE 3 In addition to the 50 A Circuit Breaker EFI Engines are equipped with additional compo AXI nent overload protection e Fuel Pump 15 A ATO Fuse e Injectors 15 A ATO Fuse e ECM 15 A ATO Fuse INDM A032 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 Indmar Marine Engines WIRING If during maintenance or inspection it becomes neces sary to move or reposition any of the engine s wiring or wire harnesses verify that wiring is returned to its origi nal position and that all harnesses are routed correctly If a wiring clip or retainer breaks replace it immediately Wiring is specifically routed to eliminate problems related to engine heat and spray or immersion in liquids Electrical problems can result if wiring is moved from its original position and is not properly repositioned General Lubrication STARTER Apply a dab of Pennzoil Premium Plus multipurpose grease onto the start
28. gines Only 5 Plugged positive crankcase ventilation system 6 Black smoke at exhaust outlet shows rich gas mixture 7 Excessive boat loads weight 8 Damaged or dirty hull 9 High altitude adjustment required 10 Adjustment for temperature extremes required Indmar Marine Engines Hard Cold Start Weak or discharged battery Choke held open Carbureted Engines Only Loose coil or ignition wires Engine Flooded Fouled spark plugs Lack of fuel at carburetor Carbureted Engines Only Battery cables loose or corroded Loose electrical grounds at engine Ignition switch problems 10 Dirt or water in fuel system 11 Engine needs tune up OONOARWN Poor High Speed Performance 1 Fouled spark plugs incorrect spark plug gap or heat range 2 Closed or partially closed choke Carbureted Engines Only Dirt or water in fuel Lack of fuel in carburetor Carbureted Engines Only Restricted exhaust system Plugged flame arrestor Oo O ON Insufficient air supply to engine Engine needs tune up Damaged or incorrect propeller Engine needs to be adjusted for high altitude operations Engine needs to be adjusted for temperature extremes engine Cranks Won t Start Doe wN Weak or shorted coil no spark at plugs Loose engine grounds Lack of fuel at carburetor Carbureted Engines Only Weak or discharged battery Boat Engine Safety switch not attached Vapor lock Idle Misses or Runs Rough N O ARO
29. he product warranty is transferable to the new owner 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 service during 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 its sole option provide a replacement of equivalent quality new or rebuilt at its option Indmar s sole obligation under this Limited Warranty 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 copy of 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 Warranty Transfer must be sent within 60 days of transfer Any transfer must be approved by Indmar In the case of transfer of a l
30. high coolant temperature stop the engine and inspect the raw water intake sea cock and sea strainer if equipped and hoses for blockage or problems 4 5 CHECK TRANSMISSION LIGHT If the engine is equipped with the Walters V Drive trans mission there is also a Check Transmission light If low oil pressure is sensed in the V Drive the light will go on indicating the problem Under normal operation the light will stay lit at idle and slow speed operation until enough pressure is produced 1200 RPM 400 RPM Extended cruising or trolling at low RPM is not harmful even if the light is lit provided that the V Drive oil level is sufficient If the oil level is normal and the light stays lit above 2000 RPM take the boat to your Indmar dealer for service ENGINE COOLING Raw water cooled engines have two water pumps One circulates water throughout the engine The other pump uses water from the sea lake or river to feed raw water to the engine This raw water pump is designed to use the water it pumps to lubricate its impeller Do not run the engine unless the boat is in water If you run the engine with the boat out of the water the water pump may be damaged causing your engine to overheat or start a fire INDM A019 Figure 4 6 Raw Water Pump AN WARNING Running engine without adequate cooling can cause engine to overheat and may result in fire explosion death and or personal seri ous injury Indmar Marine
31. ion lines with gasoline Each time you advance the ignition switch to the ON position the fuel pump cycles for 2 seconas START A a NOTICE RB Priming fuel system is not necessary with KANI carbureted engines INDM A006 Figure 1 5 Engine On Switch 9 EFI Engines Only Prime the fuel system by cycling the fuel pump eight to ten times before 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 e Repeat above eight to ten times Indmar Marine Engines NOTICE 3 The above procedure is only necessary for the first time the engine is started or in the AXINI event the fuel tank is run dry If your dealer prepares your boat for initial delivery they will perform this procedure for you 10 Start the engine Refer to Chapter 2 General Operation and Warnings and allow it to reach nor mal operating temperature keep a close eye on the gauges If any of the gauges indicate an engine problem stop the engine immediately and bring the boat to your Indmar dealer for assistance CAUTION Do not operate starter motor for more than 15 seconds without a 2 two minute cool down period Excessively long cranking times will permanently damage the starter motor and drain the battery Break In Taking care now to break in your new Indmar engine is VERY important When broken in properly your engine will last longer run
32. ith fuel components may cause a hazardous condi tion that could result in severe personal injury or death This work must be performed by your dealer s technicians AN WARNING Before starting engine operate bilge blower at least 4 minutes and raise engine cover to ventilate fumes Inspect engine and compart ment for any fluid or fuel leaks Failure to do HOW TO START YOUR ENGINE so can possibly result in fire and or explo sion resulting in death or serious injury to you and your passengers 1 Run the blower for 4 minutes to remove explosive gasoline and battery fumes from the engine compart ment Indmar Marine Engines 3 1 2 Perform the Daily Pre Start checks Refer to nek Chapter 2 General gro Operation and Warnings 3 Move the shift control lever to the NEUTRAL position Pull out the neu tral safety lever if equipped Without advancing the throttle lever turn the starter key to START position INDM A011 Figure 3 1 Blower Switch NOTICE C RB Prime cold engine by moving throttle forward and back two or three times Then return to KAN dle position before starting A hot engine does not require priming NOTICE C RB On carbureted engines it will be necessary to Al feather the throttle until the engine warms up ENGINE NOTICE ON E Because of the OFF electronic engine AXAN controls there is no need to advance the throttle Acc to set an automatic choke The throttle shoul
33. l the fuel tank s with fresh fuel and a sufficient amount of Sta Bil gasoline stabilizer to treat the entire tank Follow instructions on the container If the boat is to be placed in storage with fuel that contains alcohol the fuel tank should be drained as completely as possible and Sta Bil gasoline stabilizer added to any fuel remaining in the tank following the instructions on the container Start the engine and operate at Idle RPM until the engine reaches normal operating temperature If using a hose and adapter adjust the faucet to avoid over cooling the engine at low RPM Run the engine for at least 15 minutes to ensure that the fuel stabiliz er enters the engine s fuel system AN WARNING Running the engine with the flame arrestor removed increases the possibility of fire or explosion if engine backfire occurs and gasoline fumes are present If the engine is operated without the flame arrestor secured extreme care must be taken to ensure that the engine compartment is well ventilated and that no fuel leaks are present Indmar Marine Engines All Carefully loosen the flame arrestor and lift it far enough to insert the tube of the fogging oil can Spray 4 6 ounces 118 177 cc of oil into the throat of the carburetor or throttle body Shut off the engine Reattach the flame arrestor and seal with low tack tape Perform annual maintenance refer to Chapter 6 Scheduled Maintenance Chart Loosen all accessory d
34. ll acquaint you with basic information needed to safely operate and maintain your Indmar engine We suggest you and all other operators read the entire manual before using your boat We recommend you contact your Indmar dealer for all engine service Certified Indmar Technicians are trained They have current specifications parts and the special equipment needed to service your Indmar engine and drive 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 note the engine serial number Your dealer should have written the engine serial number on your copy of the warranty registration card Your copy of the warranty registration card should be in this Operator s Manual The serial number is stamped on the engine block see the diagram below for locations Indmar Marine Engines INDM A001 Figure 1 1 Serial Number Locations All Indmar engine ratings are determined at specific weather and elevation conditions Changes in elevation heat and humidity have a noticeable effect on the power of any engine Some power can be regained by dropping to a lower pitch propeller but the basic problem of lower air density will affect the power output of the engine If you are experiencing performance problems due to weather and or elevation conditions contact your Indmar dealer for recommendations Send your completed warranty form tod
35. lycol antifreeze is required to test the strength of the mixture 3 If the coolant level is low add a sufficient amount of coolant water mix to fill the heat exchanger Use an appropriate mix of Sierra brand antifreeze and dis tilled water mixed in accordance with the directions on the container for the anticipated temperatures 4 If the coolant in the heat exchanger is not strong enough to protect the engine to the lowest anticipat ed temperature take your boat to your Indmar dealer for replacement of coolant LS1 Fresh Water Cooled Engine 1 Remove the drain plugs on each end of the heat exchanger Do not remove center fresh water coolant plug 7 6 2 Remove the hose from the outlet side of the raw water pump Push the end of the hose low into the bilge using care not to kink it Allow both coolers to drain 3 Coat the threads of the heat exchanger drain plugs with pipe sealant and install 4 Remove the hose from the rear elbow of one of the exhaust manifolds Lower the hose into the bilge using care not to kink it Allow both manifolds to drain Drive Train Preparation 1 Change the transmission fluid and clean the filter screen following the instructions in the Transmission Owner s Manual 2 Remove the attaching hardware from the propeller shaft coupling Separate the flanges and coat the surfaces with Pennzoil Premium Plus Multipurpose grease General Power Package Preparation 1 Clean dirt grime and g
36. ne Damage to your engine caused by overheat ing is not covered by your warranty Most engines are cooled by the raw water outside of the boat Open Cooling System For this reason do not start the engine when the boat is out of the water without an engine flushing device available from your Indmar dealer With Open Cooling Systems if your engine is used in salt brackish dirty or polluted water the cooling system must be flushed with clean water immediately to prevent corrosion and blockage in the cooling system 6 8 Open Cooling Systems usually consist of a raw water intake on the bottom of the boat a strainer to filter weeds and debris a raw water pump a belt driven marine water pump a thermostat to regulate engine temperature and various connecting hoses The raw water pump pulls out side water through the strainer circulates the water through the engine and then discharges it overboard through 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 your engine is equipped with a heat exchanger tank it has a fresh water cooling system Raw water is pulled through the strainer and flows through chambers in the heat exchanger and then discharged overboard with the engine exhaust Figure 6 6 Fresh Water Cooling System Indmar Ma
37. ng the factory your engine was tested for operational performance Operational performance data will be retained to track product performance in the future It s our goal to continually improve our product and deliver all the benefits of the latest power technology If you have any questions concerning your engine please feel welcome to contact Indmar Customer Service at 901 353 9930 or E Mail us at gearhead l ndmar com You can write us at Indmar Products Company Inc 5400 Old Millington Road Millington Tennessee 38053 On the Web go to our site at www indmar com Again thank you for choosing Indmar We wish you safe trouble free boating Sincerely Team Indmar Indmar Marine Engines iii TABLE OF CONTENTS IMTOUCUO rt le v Chapter 1 First Time Operation and Break In 1 1 Chapter 2 General Operations and Warnings 2 1 Chapter 3 Engine Starting Procedures o o 3 1 Chapter 4 Normal Operation 0000 cee eee eee 4 1 Chapter 5 Fuel secano y pe ds e A e as 5 1 Chapter 6 Maintenance coccoccccococco 6 1 Chapter 7 Storage and Winter Lay up oocococo o 7 1 Chapter 8 Troubleshooting 020 e eee eee eee 8 1 Appendix A Maintenance Components and Fluids A 1 Appendix B Engine Specifications B 1 Appendix C Limited Warranty 000 eee C 1 Indmar Marine Engines INTRODUCTION This manual wi
38. ngevity the wide open throttle WOT engine operation must be near the top of but within the specified WOT operating range To adjust the WOT operating range you must select a pro peller propping with the proper diameter and pitch The propeller which was supplied with your boat was chosen by the boat builder for best all around performance under average conditions Load weather altitude and boat condition all affect WOT engine operation If you use your boat for several differ ent applications such as wakeboarding barefooting and cruising it may be necessary to have 2 or more pro pellers which will allow the engine to operate in the WOT range for each application Propping the boat should be done after engine break in and the initial 10 hour dealer check The boat should be loaded the way it would normally be for each application For instance if you are propping for wakeboarding fill the ballast tanks if equipped and add all the people and gear you would normally expect to carry in the boat Take the boat out and after warm up run it at wide open throt tle and note the maximum RPM EFI Engines are equipped with RPM limiters to prevent over revving Take note if the RPM limiter is activated If the WOT RPM is higher than the maximum RPM in your engine s WOT operating range the boat is under propped Install a higher pitched propeller to reduce WOT RPMs An engine that is over revving may quickly experience catastrophic
39. nock sensor Torque specification for the knock sensor is 14 16 Ib ft 19 to 21 5 Nom On Walter V Drive units coat the threads on the drain plugs with pipe sealant and reinstall on the front and rear of the transmission housing Reinstall the raw water pump impeller be sure to use a new gasket for the housing cover Re attach the inlet and outlet hoses to the raw water pump Reattach the large diameter hose to the water circu lating pump Reattach the water hose to the transmission cooler On fresh water cooled models reattach the raw water inlet and outlet hoses Install a new set of spark plugs in the engine Inspect accessory drive belts and tighten to the prop er tension if necessary Check condition of the distributor cap and rotor and replace if worn damaged or corroded If the fuel tank was drained fill tank with fresh fuel that does not contain alcohol Check all fluid oil and coolant levels on engine and drive train Check engine compartment and bilge for nesting ani mals Clean as necessary Check for any damage or evidence of fluid leaks 15 Remove tape from flame arrestor Check alignment NOTICE between the output flange on the transmission and With the boat in the water or a hose and the prop shaft flange If the maximum feeler gauge E Pie dapter installed cycle the key switch ON that can slip between the flange faces at any point is 3 h 0 003 0 08 mm the unit is properly aligned If a Mella
40. o work with the stan dard electronics installed in your boat If you AXAN add electrical components or accessories you could change fuel injection controls for your engine or could exceed the amperage capacity of the wiring and protection system Before adding electrical equipment consult your Indmar dealer Indmar Marine Engines Chapter 4 NORMAL OPERATION DAILY ROUTINE 1 Open the engine cover and check the bilge for water pump bilge dry Excessive amounts of water can 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 CAUTION Do not allow excessive amounts of water to remain in the bilge Component damage due to water is not covered by the warranty 2 Follow the starting procedures outlined in Chapter 3 Engine Starting Procedures Indmar Marine Engines AN WARNING Don t forget to run your engine blower for at least 4 minutes before cranking engine Failure to do so may result in fire and or explosion 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 EFI engines including the LS1 are programmed with a phased warm up to ensure that the engine is warm before full RPM is possible refer to Table
41. oat in the spring Indmar Marine Engines Raw Water Cooled Engines 1 Remove the petcock drain plug or sensor from each side of the engine Indmar suggests removing the petcocks completely not just opening the petcock drain valve NOTICE 3 Some 5 7 Liter engines have a knock sensor located in the drain location The knock sen AXINI sor must be carefully removed to drain that side of the block NOTICE On the 8 1 Liter engine removing the knock sensor does NOT drain the block Remove the plugs from the brass fillings on both sides of the engine to drain water from the block NOTICE Placing the drain plugs in a plastic bag and attaching it to the steering wheel of the boat will act as a reminder to reinstall the drain plugs during recommis sioning in spring 2 Use a short piece of stiff wire and poke around in the drain hole to ensure that any rust or scale is broken apart and the engine drains completely 3 Disconnect the large diameter hose that runs from the water circulating pump to the thermostat housing Make sure all of the water drains from the hose 7 5 Fresh Water Cooled Engines Except LS1 1 Remove the raw water inlet and outlet hoses from the intake side of the heat exchanger 2 Check the level of the coolant on the freshwater side of the heat exchanger Use the anti freeze tester to test the strength of the mixture NOTICE A special antifreeze tester designed to be used with Propylene G
42. old key in START position for 3 5 seconds If engine still does not start advance throttle lever about 1 4 of its total travel Turn key and hold it there for 12 more seconds until engine starts If your engine does not start after several attempts it may 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 is pulled out or Neutral lockout button 2 activated so that boat is still in NEUTRAL 2 Wait for 30 seconds to allow starter motor to cool 3 3 INDM A016 Figure 3 4 Shift Throttle Lever Advance throttle lever to full throttle position and hold Hold key in START position for no more than 10 seconds to clear extra gasoline from the engine When engine starts immediately return throttle han dle to IDLE position If it does not start wait two minutes and try the sequence 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 not start advance throttle to about 1 4 while holding key in the START position Remember you should only hold key in start position for 12 seconds at a time When engine starts release the key and immediately return throttle to IDLE position NOTICE 3 Your engine is designed t
43. on Failure to do so may result in fire or explosion and may Explosive gasoline and battery fumes may cause death or serious injury accumulate in your engine compartment Failure to properly ventilate fumes with the bilge blower may result in explosive atmos phere resulting in death or serious injury to you and your passengers Indmar Marine Engines 2 1 AN WARNING Never remove or modify any components of the engine s fuel system Tampering with fuel components may cause a hazardous condi tion that could result in severe personal injury or death This work must be performed by your dealer s technicians Daily Pre Start Checks Refer to Chapter 6 Maintenance for checks and services dOVOOUVOODDELE Figure 2 1 Pre Start Check Points INDM A007 Verify boat hull and or garboard drain plug are in place Carefully inspect engine compartment for signs of fluid leakage and proper ventilation Unlike autos marine engine compartments require positive ventila tion and air re circulation to ensure that flammable and explosive vapors are safely dispersed in an envi ronmentally sound manner Verify engine drain plugs are in place Check engine oil level ee tie INDM A008 Figure 2 2 Engine Oil Dipstick Verify fuel lines are tight and there is no leakage present Inspect oil lines and oil filter Ensure they are tight and no leakage is present Indmar Marine Engines 13
44. or 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 556003 Spin on Indmar786020 Indmar Marine Engines A 1 Alternator Belt All 5 7 Liter except LS1 Indmar 725018 LS1 serpentine Indmar 725028 8 1 Liter Indmar 725030 Thermostat Raw water cooled Indmar 985009 Closed cooled Indmar 986034 LS1 Indmar 986110 Spark Plugs All 5 7 Liter except LS1 AC Delco MR43LTS LS1 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 A 2 Indmar Marine Engines Appendix B ENGINE SPECIFICATIONS 5 7L Carb 5 7L TBI 5 7L MPI LS1 Corvette 8 1L MPI Number of Cylinders V 8 Displacement 350 CID 5 7L 496 CID 8 1L Bore Stroke 3 898 x 3 622 in 4 25 x 4 37 in 4 0012 x 3 480 in 101 63 x 88 39 mm 99 x 92 mm 108 x 111 mm Compression Ratio 9 4 1 10 1 1 9 1 1 Compression Pressure Note 1 Minimum 100 PSI 690 kPa Idle RPM in Neutral Note 2 650 50 RPM Operating Range at WOT 4400 4800 RPM 4600 5200 RPM 5200 5600 RPM 5000 5400 RPM Oil Pressure at Idle 4PSI 41kPa Minimum Hot 5 PSI 34kPa Minimum Oil Pres
45. rate reading 5 MANUA OPERATING RANGE O SEE OWNER Am INDM A003 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 add only enough oil to return level to FULL mark INDM A025 Figure 6 3 Engine Oil Fill Indmar Marine Engines CAUTION Do not overfill If your oil level is above the full mark on the dipstick the engine may be damaged Indmar uses and recommends Pennzoil Marine 15W 40 Marine Oil API Service SJ CG4 or equivalent If engine is to be used on conditions below 20 F 7 C use Pennzoil Marine SAE 10W 30 API Service SJ CD or equivalent CAUTION The use of engine oil other than 15W 40 with an API SJ CG4 designation can cause engine damage Damage to your engine caused by the use of improper oils is not covered by your warranty Synthetic Oil Synthetic oil that meets our requirements of 15W40 and API SJ CG4 is acceptable to use after 100 hours of operation with the recommended oil The use of synthetic oil does not change the requirement of 50 hour oil change intervals Indmar Marine Engines Changing Oil Change your engine oil after the first 10 hours of opera tion Then change oil every
46. rease from painted surfaces of the engine and drive train 2 Touch up painted areas of the engine and transmis sion 3 Lubricate throttle and shift linkages and cables with Pennzoil Premium Plus Multipurpose Grease Indmar Marine Engines 4 5 Spray the whole engine with Pennzoil Marine Z M Corrosion Protectant and Lubricant Disconnect the battery cables from the battery and charge the battery fully If you remove the battery from the boat store it in a cool and dry place Leave the engine box cover propped open about 2 50 mm to ventilate the engine compartment REACTIVATING ENGINE AFTER EXTENDED STORAGE CAUTION Use caution when connecting the battery cables Improperly connecting the battery cables or using the wrong battery type can damage electrical components These dam ages are not covered by your warranty Charge and reinstall the battery in the boat Make sure terminals are clean and tight Coat the threads of the manifold drain plugs with pipe sealant and Install the manifold drain plugs in the back of the exhaust manifold and or reconnect exhaust manifold drain hoses Coat the threads of the block drains and petcock drains with pipe sealant and install in the engine block EFI engines have a knock sensor located in Indmar Marine Engines 1d 12 13 14 one of the drain holes If your engine has a knock sensor it must be reinstalled without using thread sealant Do not over tighten the k
47. rine Engines Check coolant level every time you check your oil The level in the expansion tank should be maintained at 2 3 full when the engine is at operating temperature AN WARNING To avoid possible skin burns the engine must be turned OFF and cool enough so no heat is registered on the temperature gauge Only after the engine is completely cooled is it safe for you to remove the coolant reser voir cap to check the level Failure to follow procedure may result in death or serious per sonal injury CAUTION Failure to maintain the coolant at the proper level can cause engine damage Your warran ty will not cover engine damage due to over heating or any other cause associated with improper coolant levels Use only propylene glycol coolant Use of any other coolant or mixing coolant types can cause engine damage Damage to your engine from use of any other type of coolant is not covered by warranty Indmar Marine Engines The coolant system should be flushed and coolant replaced every two years This should be performed by a qualified Indmar service technician When adding coolant add only Sierra brand propylene glycol in an appropriate mixture with distilled water in accordance with the directions on the container Do not overfill the tank Do not mix anti freeze types If tank is completely empty see your Indmar dealer for assistance immediately to purge system Purging the system is a difficult p
48. rive belts and check condition Replace belt s if cracked or damaged Drain seawater section of the cooling system Engines Drain water from exhaust manifolds Uncouple the hose quick disconnect and drain the manifolds Indmar recommends that you leave the drain plugs out or the hose uncoupled until spring Remove both hoses from the seawater pump on the front of the engine Drain any remaining water from the hoses Remove the raw water pump impeller from the pump housing Replace the impeller if it shows any signs of damage or wear Lubricate the impeller with Vaseline and seal in an airtight bag Indmar Marine Engines i PID cig Lg 077 INDM A038 Figure 7 1 Quick Disconnect INDM A036 Figure 7 2 Raw Water Pump Impeller 4 Remove the hose from the lower rear end of the transmission cooler Inspect the cooler for any debris such as weeds plastic etc INDM A009 Figure 7 3 Transmission Cooler On Walters V Drive equipped units remove the two small square headed drain plugs from the front and rear of the upper housing Look for the words Water Drain on the housing Indmar Marine Engines WATER LINE WATER DRAIN INDM A040 Figure 7 4 V Drive Drain Plugs NOTICE Placing the drain plugs impeller etc in a plastic bag and attaching the bag to the steering wheel of the boat is a good reminder to reinsert the plugs when you recommission the b
49. rly until the old fuel is used up Indmar will not pay for repairs to carburetors or fuel injection compo nents that are inoperable or damaged from old and or poor quality fuel USING OXYGENATED FUELS OR FUELS WITH ALCOHOL MBTE methyl butyl tertiary ether is an oxygenate and octane enhancer This compound may be blended with fuel Fuel that is no more than 15 MBTE is acceptable for use in your Indmar engine Indmar Marine Engines Ethyl alcohol ethanol or grain alcohol is acceptable as long as it is a blend and the blended fuel contains no more than 10 ethanol CAUTION Fuels that are blended to contain methanol or wood alcohol should not be used in Indmar engines These fuels can corrode metal parts in your fuel system and engine Fuels that contain methanol will damage your engine Damage caused by the use of fuels that contain methanol is not covered by your warranty Indmar Marine Engines FUELS IN OTHER COUNTRIES If you operate your Indmar engine outside the USA or Canada unleaded fuels may be difficult to obtain Leaded fuels are not recommended as engine compo nents will last longer using unleaded fuel Indmar Marine Engines Chapter 6 MAINTENANCE GENERAL SERVICE NOTES Your Indmar dealer is your best source for engine repair and maintenance Indmar certified technicians attend ongoing service training programs and have the proper diagnostic tools plus the latest specifications for your
50. rocedure that is not recommended for the boat owner FUEL SYSTEM The fuel system consists of a fuel filter water separator fuel pump and an unused fuel recovery system Fuel in the system is under pressure and must be relieved before servicing Because of the inherent danger of fuel leakage into the bilge do not attempt servicing or main taining components of the fuel system Your Indmar dealer has factory trained technicians and U S Coast Guard approved marine grade parts required for fuel systems 6 9 TRANSMISSION Indmar engines are equipped with one of three types of marine transmissions Midships Mount ZF Hurth Marine In Line e Stern Mount ZF Hurth Marine V Drive Stern Mount Walters V Drive and ZF Hurth In Line A separate owner s manual covering basic maintenance is provided with each transmission The transmission fluid must be changed and the filter cleaned after the first 10 hours of operation and once each year thereafter Refer to the transmission owner s manual for information n LL NES x Figure 6 7 ZF Hurth Transmission Dipstick Location The transmission is water cooled by a heat exchanger INDM A030 6 10 connected to the engine cooling system The transmission fluid level should be checked each time the engine oil is checked Fluid level is to be maintained at a level between the Full and Add marks on the transmission dipstick Overfilling the transmission with
51. rt condition verify that this switch has not been disabled If the tether cord is pulled from the switch it dis ables the ignition system so the boat cannot start Use caution while operating shift lever Shift only while the engine is at idle INDM A017 Figure 4 3 Tether Cord and Safety Switch CAUTION Avoid using the throttle when in reverse This can force water backwards into the exhaust system and into the engine cylinders with major damage Indmar Marine Engines CAUTION HYDROSTATIC LOCK If water collects in the engine cylinder for any reason it can cause hydrostatic lock not allowing the pistons in the engine to move properly Hydrostatic lock can severely damage your engine which is not 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 in the drive line will cause excessive wear on transmission and engine components If you believe you hit something with the propeller or if you notice excessive vibration see your dealer Damage to your engine drive line or transmission caused by vibration is not covered by your warranty FUEL SYSTEM The Indmar fuel system uses high quality marine grade components These components will tolerate small amounts of water wi
52. sor 1 1 3 Make sure your battery is fully charged and the cables are clean and tight 4 Check engine oil for correct level Refer to Chapter 6 Maintenance S MANUA OPERATING RANGE O SEE OWNER LE INDM A003 AL Figure 1 3 Engine Dipstick Level 5 Check transmission oil level for correct level Refer to Chapter 6 Maintenance 6 If your engine is equipped with fresh water cooling check the expansion tank for the correct level Refer to Chapter 6 Maintenance CAUTION Do not mix antifreeze types 7 Inspect engine mounts to make sure they aligned and tight Make sure that the propeller shaft coupler bolts are tight AN WARNING Make sure the engine water intake is not blocked by the trailer bunk Blocked or restricted water flow may damage the engine 1 2 8 Back trailer into the water Make sure the engine water intake is submerged AN DANGER 1 Before starting engine operate bilge blower at least 4 minutes and raise engine cover to ventilate fumes Inspect engine and compart ment for any fluid or fuel leaks Failure to do so can possibly result in fire and or explo sion resulting in death or serious injury to you and your passengers A Figure 1 4 Raised Engine Cover Indmar Marine Engines NOTICE ON 3 Priming the EFI Fuel OFF _ System is required E Mella before starting your EFI engine for the first time ACC This allows the electric fuel pump to fill the fuel inject
53. sure at 2000 RPM 18 PSI 124 kPa Minimum Hot 10 PSI 69kPa Minimum Oil Filter Pennzoil PZ3 AC PF25 AC PF454 Napa Gold 1042 Fuel Pump Pressure 8 PSI Max 30 PSI Min at sai 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 Ground Minimum Battery Requirements 650 cca 700 mca 120Ah Firing Order 1 8 4 3 6 5 7 2 1 8 7 2 6 5 4 3 Spark Plug Type MR43LTS AC 41 931 Nippon Denso TJ14R P15 Spark 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 Adjustable Thermostat Indmar Marine Engines 160 F 71 C Fluid Capacities 5 7L Carb 5 7L TBI 5 7L MPI LS1 Corvette 8 1L MPI Crankcase 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 Used Hurth V Drive Transmission Note 4 4 4 Quarts 4 16 L Notes 1 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 Timin
54. sure you have the knowledge experience engine damage and void your warranty and the correct replacement parts BEFORE you attempt any repairs Be sure all fasteners you use are approved and rated for marine use Use of improper parts can cause component or engine failure which may result in death or serious person al injury 6 2 Indmar Marine Engines Scheduled Maintenance Chart FIRST EVERY EVERY EVERY 300 EVERY 10 50 100 HOURS or 2 ITEM SERVICE HOURS HOURS HOURS ANNUALLY YEARS Engine Oil amp Filter Change X X X ZF Transmission Fluid Change X X Walters V Drive Oil Change X X Engine Coolant Change X Fuel Filter Replace X X X Spark Plugs Replace X Engine Timing Check X X Engine Tune Up X Flame Arrestor Clean Change X Belts Inspect X X X Shaft Alignment Check X X Spark Plug Wires Inspect X Raw Water Pump Impeller Inspect X X Breather Hose Clean X PCV Valve Replace X Starter Bendix Grease X X Services best accomplished by your Indmar dealer Indmar Marine Engines 6 3 ENGINE OIL Checking Oil ee o INDM A023 Figure 6 1 Engine Oil Dipstick Location Check the oil level with the dipstick every time you get fuel To get an accurate reading your engine should be warm and the boat should be level For best results wait about 2 minutes after you turn off the engine to allow the oil to drain into the oil pan giving you a more accu
55. then OFF for five second intervals 8 10 times thicker gauge can be inserted at any point the before cranking the engine to allow the fuel pump to engine must be readjusted until proper alignment is prime the fuel lines obtained l l 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 on the gauge readings Check all of the hoses and drain plugs for leaks Listen for abnormal noises Run the engine long enough to reach normal operating tem perature and re inspect for leaks If no leaks are found the boat is ready for operation INDM A037 Figure 7 5 Prop Shaft Flange Alignment 7 8 Indmar Marine Engines Chapter 8 TROUBLESHOOTING Your Indmar engine is manufactured under strict quality control standards lt is tested along with a full spectrum gas analysis It is operating at optimum levels before it is shipped Indmar engines have the exclusive Indmar 3 year limited warranty Difficulties can occur Use the following problem diagnosis charts to help pinpoint problems In most cases you will need the assistance of your Indmar deal er to correct the cause of the problem Poor Gas Mileage 1 Fouled spark plugs 2 Plugged flame arrestor 3 Poor driving habits 4 Closed or partially closed choke Carbureted En
56. ther rights which vary from state to state Indmar Products Co Inc 5400 Old Millington Road Millington Tennessee 38053 Indmar Marine Engines
57. thout sustaining damage Your engine will misfire and run poorly however if water is in the fuel Use caution when re fueling not to allow water to enter the fuel system If you suspect your fuel is water contaminated consult your dealer and avoid that fuel source in the future AN WARNING Do not attempt to repair or replace any compo nents of the fuel system They are special marine parts and may require special service tools You could damage the fuel system by not using specified tools This could cause a fire 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 a replacement is needed use only a marine battery with minimum 650 cold cranking amps at 0 F 18 C 4 4 Before disconnecting the battery make sure the battery switch if equipped ignition key and all accessories are in the OFF position Be sure to connect cables properly Black cable to the negative or post Red cable to the positive or post INDM A010 Figure 4 4 Marine Battery Indmar Marine Engines CAUTION Use caution when connecting the battery cables Improperly connecting the battery cables or using the wrong battery type can damage electrical components These dam ages are not covered by your warranty CHECK ENGINE LIGHT EFI ENGINES ONLY Some boats are

1994-2002

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