Crusader 5.7L Carburetor - User Manual

OWNER’S OPERATION
and
MAINTENANCE MANUAL
A Division of

Summary

Service and Warranty

Safety Information

Information and instructions to alert users of possible safety hazards.

Replacement Parts

Guidance on using approved replacement parts to minimize fire or explosion hazards.

Safety Warnings

Definitions of DANGER, WARNING, CAUTION, and IMPORTANT signals for safety.

Crusader Marine Engines Commitment to You

Commitment to customer satisfaction and dealer involvement.

Owner Warranty Registration

Process for registering the engine warranty with the factory for validity.

Engine Operation and Care

Guidance on operating and maintaining the engine for optimal performance.

Maintenance Records

Importance of retaining receipts for regular maintenance to avoid warranty issues.

Local Repair Service

How to obtain service or make a claim through the selling dealer.

Service Away From Home

Procedure for obtaining service when away from the local dealer.

Replacement Part Inquiries

Directing inquiries for replacement parts to the local authorized dealer.

Replacement Service Parts

Warning about using non-approved replacement parts in electrical, ignition, and fuel systems.

Applicable Limited Warranty

Details the limited warranty applicable to engines sold in the US and Canada.

One Year Limited Warranty

Specific terms and conditions of the one-year limited warranty.

Items Not Covered Under Limited Warranty

List of common service types and damages not covered by the warranty.

Things You Should Know About The Warranty

Information on warranty repair exchanges, production changes, proof of purchase, and access.

Marine Transmissions

Information on transmissions supplied by other manufacturers and how to contact them.

Resolving a Service Problem

Steps to follow for resolving service or warranty problems with the dealer or distributor.

Crusader Master Distributors

Listing of distributors for service assistance and contact information.

Dealers Responsibilities

Responsibilities of the dealer, including pre-delivery inspection and customer familiarization.

Transferable Warranty

Details on transferring the limited warranty to a subsequent purchaser.

Direct Sale By Owner

Procedure for registering a new owner and retaining the unused portion of the warranty.

Boating Responsibilities

Carbon Monoxide Hazard

Dangers of carbon monoxide and how to prevent poisoning on boats.

Safe Boating Suggestions

Recommendations for safe boating practices and seamanship courses.

Water Wisdom

Suggestions for safe boat operation to ensure the safety of self and passengers.

Operation and Maintenance

Owner's responsibility for safety checks and adhering to maintenance schedules.

Rules of the Road

Explanation of channel buoy guide, horn signals, and general navigation rules.

Engine Identification

Engine Identification

Information on where to find engine model and serial number for service.

Owner Identification and Registration Information

Recording owner and engine details for quick reference during service or warranty.

2004 Model Identification; Advisory

Guide to decoding the model number for identification and specifications.

Operating Instructions

Instrumentation

Explanation of typical boat instrumentation and their functions.

Engine Alarm System

Purpose and operation of the engine alarm system for potential problems.

Remote Controls

Information on various types of remote controls and caution for shifting.

Starting Engine

Detailed procedure for safely starting the engine, including pre-start checks.

Shifting Transmission

Procedure for shifting the transmission between forward, reverse, and neutral gears.

Stopping Engine

Procedure for safely stopping the engine, including cool-down period.

Freezing Temperature Operation

Measures to protect the cooling system from freeze damage.

Operation in High Debris Areas

Recommendations for operating in areas with high debris to prevent cooling system issues.

Conditions Affecting Operation

Trim and Weight Distribution

How trim and weight affect boat handling and performance.

Boat Bottom

Importance of keeping the boat bottom clean for engine performance and preventing overheating.

Propeller Selection

Guidance on selecting the correct propeller for optimal performance and engine life.

Engine Break-in Period

Engine Break-In Period

Guidelines for the first 25 hours of operation to ensure maximum performance and longevity.

25-Hour Engine Inspection

25-Hour Engine Inspection

Recommended maintenance checks and adjustments after the first 25 hours of operation.

Fuel Requirements

Gasoline Requirements

Specification for required gasoline octane and warnings about misuse.

Gasoline Containing Alcohol

Recommendation against using gasoline containing alcohol due to potential engine issues.

Piston Damage Due To Detonation and;or Pre-Ignition

Causes and consequences of detonation and pre-ignition on engine parts.

Oil Requirements

Engine Oil Recommendations

Recommendations for engine oil viscosity and warnings about additives.

Synthetic Oils

Statement that synthetic engine oils are not recommended.

Oil Change Intervals (Common)

Recommended intervals for changing crankcase oil and oil filter.

Transmission and “V”-Drive Oil Requirements

Recommended oil classification and viscosity for transmissions and V-Drives.

Engine Maintenance

Engine Maintenance

Overview of maintenance procedures and recommendations for consulting repair manuals.

Checking Fluid Levels

Procedure for checking and filling engine crankcase oil, with cautions.

Transmission Fluid

Procedure for checking and filling transmission fluid, with cautions.

Lubrication

Lubrication points for throttle cable, shift cable, and shift lever.

Electrical System Circuit Breaker

Function of the main circuit breaker for overload protection and resetting.

Electrical System Fuses

Location and function of fuses, specifically the fuel pump fuse.

Ignition Fuse

Troubleshooting steps if the engine will not crank, focusing on the ignition fuse.

Electrical System Wiring and Connectors

Importance of checking wiring and connectors for loose or damaged connections.

Battery

Safety warnings and guidelines for handling and maintaining the battery.

Fresh-Water Cooling System Sacrificial Zinc Anode

Location and inspection procedure for zinc anodes in the cooling system.

Checking Coolant Level

Procedure for checking and adding coolant to the degas bottle.

Flushing Cooling System - Sea-Water Section

Procedure for flushing the sea-water section of the cooling system.

Testing Coolant For Alkalinity

Method for testing coolant alkalinity using litmus paper.

Draining Fresh-Water Cooling System

Procedure for draining coolant from the fresh-water cooling system.

Filling Fresh-Water Cooling System

Procedure for filling the fresh-water cooling system with DEX-COOL™ coolant.

Cleaning Sea-Water Section of Heat Exchanger

Procedure for cleaning the sea-water section of the heat exchanger.

Fuel System Description

Overview of the fuel system, including flame arrestor and electric fuel pump.

Flame Arrestor

Procedure for checking and cleaning the flame arrestor.

Drive Belt Inspection

Procedure for inspecting the drive belt for wear and damage.

5.7 L Accessory Drive Belt

Details on the serpentine belt for the 5.7L engine and its components.

Drive Belt Replacement (5.7 L)

Step-by-step instructions for replacing the serpentine drive belt.

Servicing Raw Water Pump Impeller (5.7 L)

Recommendation for servicing the raw water pump impeller.

Changing Oils

Procedure for changing engine oil and filter, including environmental warnings.

Engine Alignment

Procedure for aligning the engine to the propeller shaft for optimal performance.

Engine Maintenance Log

Log for recording maintenance and repair activities with operating hours.

Maintenance Schedule

Schedule outlining required maintenance tasks and their frequencies.

Visual Inspection

Importance of visually inspecting the engine assembly at regular intervals.

Engine Fluid Capacities

Table listing engine oil and cooling system capacities.

Transmission Fluid Capacities

Table listing transmission fluid capacities for various models.

Filter Requirements

List of required filters and their part numbers.

Engine Specifications

Engine Specifications

Detailed specifications for the 5.7L engine, including dimensions and operating parameters.

Tune-Up Specifications

Specifics for spark plugs, timing, idle mixture, and firing order.

Out-of-Season Storage

Engine Storage

Procedure for preparing the engine for storage, recommended to be done by a dealer.

Draining Instructions

Instructions for draining the cooling system for storage, distinguishing between fresh and sea-water cooled.

Battery Storage

Guidelines for proper battery storage to prevent damage.

Out-of-Season Engine Warm-Up

Procedure for starting the engine during cold weather storage.

Recommissioning After Storage

Steps for recommissioning the engine after it has been in storage.

Troubleshooting

Engine will not crank with the starter motor, or cranks slowly.

Possible causes and corrective actions for engine cranking issues.

Engine Cranks - will not start or is hard starting.

Possible causes and corrective actions for engines that crank but do not start.

Engine Overheats

Possible causes and corrective actions for engine overheating.

Insufficient engine temperature

Possible causes and corrective actions for low engine operating temperature.

Engine oil pressure low

Possible causes and corrective actions for low engine oil pressure.

Transmission slipping - erratic operation

Possible causes and corrective actions for transmission slipping or erratic operation.

Engine misses, runs rough

Possible causes and corrective actions for an engine that misses or runs rough.

Poor engine or boat performance

Possible causes and corrective actions for general poor engine or boat performance.

Water Flow Diagrams

Fresh-Water Cooling System (5.7 L)

Diagram illustrating the fresh-water cooling system flow and components.

Engine Harness Wiring Diagrams

Wire Harness Color Chart

Chart matching circuit numbers and names to engine harness wire colors.

Typical Engine Wiring w;Mallory Ignition

Diagram illustrating typical engine wiring with Mallory ignition system.

Literature

Literature

Contact information for obtaining service and parts literature from Crusader Marine Engines.

Forms

Summary of Warranty Term Limits

Outline of year and hour limits for different Crusader engine models.

Crusader Ownership Change Notice

Form to inform Crusader of ownership changes for warranty notification purposes.

Crusader Warranty Transfer Application 2004 (PORT OR SINGLE ENGINE)

Application form for transferring the Crusader limited warranty to a new owner.

Crusader Warranty Transfer Application 2004 (STARBOARD ENGINE)

Application form for transferring the Crusader limited warranty to a new owner for starboard engines.

Notes

Notes

Blank page for user notes.

Crusader 5.7L Carburetor Specifications

General

Brand	Crusader
Model	5.7L Carburetor
Category	Engine
Language	English