Table of Contents
2 VPA 7743722 English 10-2004
Salt Water Operation ..................................................44
Trailering Your Boat....................................................44
Features 45
Circuit Breakers and Fuses.................................... 45
Legend of Symbols Used in Engine Diagrams ...........45
3.0GLP-C ............................................................... 46
4.3GL-D, 5.0GL-E .................................................. 48
4.3GXi-E, 5.0GXi-E, 5.7Gi-E, 5.7GXi-F ................. 50
8.1Gi-F, 8.1GXi-E................................................... 52
4.3GXi-EF, 5.0GXi-EF, 5.7Gi-EF, 5.7GXi-FF......... 54
8.1Gi-FF, 8.1GXi-EF .............................................. 55
SX-M Sterndrive..................................................... 56
DP-S Sterndrive ..................................................... 57
Maintenance Parts List 59
Maintenance 61
Engine Break-in Period .......................................... 61
Break-in Procedures ...................................................61
First Two Hours ..........................................................62
Next Eight Hours.........................................................62
Final Ten Hours ..........................................................63
First Service Inspection (Dealer 20-Hour Check) .......63
Operating After Break-in Period..................................63
Maintenance Schedule........................................... 64
Static Water Line.................................................... 66
Static Water Line Test ................................................66
Preparing for Boating (Launching)..............................67
Off-Season Storage (Winterization)............................67
Maintenance of Boat’s Systems............................. 68
Engine Exhaust System..............................................68
Drive Unit Bellows.......................................................68
Fuel System................................................................69
Gasoline Recommendations .................................69
Gasoline Containing Alcohol.................................70
Detonation (Spark Knock) .....................................70
Preventing Gum Formation and Corrosion ...........70
Carburetor (GL).....................................................71
Electronic Fuel Injection (Gi, GXi).........................71
Flame Arrestor ......................................................71
Electric Fuel Pumps ..............................................72
Fuel Filter ..............................................................72
Engine Fuel Filter Replacement............................73
Fuel Filter Replacement (V6/V8 Carb Engines) ....74
Fuel Screen Cleaning (3.0 Liter Carb Engines) ....74
Electrical System ........................................................75
Battery Cables.......................................................75
Batteries and Connections ....................................75
Battery Replacement.............................................77
Multiple Batteries and Selector Switch..................78
Distributor Cap and Rotor .....................................78
Circuit Breakers and Fuses...................................78
Spark Plugs...........................................................79
Checking and Changing Spark Plugs ...................79
Belt Adjustments.........................................................81
Serpentine Belt Engines........................................81
V-Belt Engines ......................................................82
V-Belt Tension.......................................................82
Power Steering Pump Belt....................................83
Alternator Belt....................................................... 83
Cooling System .......................................................... 84
Raw Water System............................................... 84
Closed Cooling System (F-Series) ....................... 84
Engine Overheating (Gi & GXi only) ..................... 84
Engine Overheating (All other Models)................. 85
Engine Flush .............................................................. 85
Draining the Cooling System...................................... 86
Raw Water Cooled Engines.................................. 86
Draining the Closed Cooling System.......................... 87
8.1 Liter Engines (F-Series).................................. 87
4.3 GL Draining Only ............................................ 87
4.3, 5.0, and 5.7 Liter Engines (F-Series)............. 87
Impeller: Checking & Replacing ................................. 88
Steering System ......................................................... 88
Power Steering Reservoir Fluid Level .................. 89
Power Trim/Tilt Fluid Level......................................... 89
Shaft Spline and Bearing Lubrication ......................... 89
Tie Rod (Twin Installations Only) ............................... 89
Lubrication System................................................. 90
Engine/Crankcase Oil................................................. 90
Checking Engine Oil Level ......................................... 91
Changing Engine Oil .................................................. 91
Changing the Oil Filter................................................ 91
Drive Components.................................................. 92
Drive Unit Lubrication ................................................. 92
Checking the Drive Unit Lubricant ........................ 92
Draining the Drive Unit.......................................... 92
Filling the Drive Unit.............................................. 93
Sacrificial Anodes....................................................... 94
Replacing Sacrificial Anodes ................................ 94
Replacing Heat Exchanger Anodes...................... 94
Active Corrosion Protection System........................... 95
Painting the Drive ....................................................... 97
SX and DP-S Drives ............................................. 97
Preparation ........................................................... 97
Paint Application................................................... 97
Propeller Care ........................................................ 98
Propeller Replacement — SX .................................... 98
Removing the SX Propeller .................................. 98
Installing the SX Propeller .................................... 98
Propeller Replacement — DP-S................................. 99
Removing the DP-S Propeller............................... 99
Installing the DP-S Propeller................................. 99
Boat Bottom.......................................................... 100
Bottom Painting ........................................................ 100
Engine Alignment ................................................. 100
Engine Submersion .................................................. 100
Replacement Parts............................................... 101
Troubleshooting 103
Troubleshooting - System Isolation ...................... 103
Engine Troubleshooting Guides ........................... 104
Technical Data 113
Metric Conversion Chart 121
Index 123
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