Crusader 5.7L Carburetor Guide d'installation

OWNER’S OPERATION

and

MAINTENANCE MANUAL

A Division of

Welcome to the growing family of Crusader Marine Engines owners. We are delighted you have chosen Crusader

power for your boat and wish you many years of enjoyment.

READ THIS MANUAL THOROUGHLY

Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand

any portion of the manual, contact your Dealer for clariﬁcation or assistance. Ask your Dealer for a demonstration of

actual starting and operating procedures.

The descriptions and speciﬁcations contained in this manual were in effect at the time of printing. Crusader Marine

Engines’ policy of continued improvement reserves the right to change speciﬁcations or design without notice and

without obligation.

This manual will cover the following Crusader engines:

Year Model

2005 5.7L Carburetor

Part Number - L510019-05 Printed 12/04

L510019-05

1 - SERVICE AND WARRANTY ............................................................................................... 4-17

Safety Information ...................................................................................................................... 4

Replacement Parts ........................................................................................................................... 4

Safety Warnings ......................................................................................................................... 4

Crusader Marine Engines’ Commitment to You ................................................................................. 5

Owner Warranty Registration (Warranty Registration Card is located at the back of this manual) ................ 5

Engine Operation and Care .......................................................................................................... 6

Maintenance Records ................................................................................................................. 6

Local Repair Service ................................................................................................................... 6

Service Away From Home ............................................................................................................ 6

Replacement Parts Inquiries ......................................................................................................... 7

Replacement Service Parts .......................................................................................................... 7

Applicable Limited Warranty ......................................................................................................... 7

Crusader Marine Engines One-Year Limited Warranty

(For Engines Sold and Used in the United States and Canada) ........................................................... 8

Items Not Covered Under the Limited Warranty ............................................................................... 10

Things You Should Know About The Warranty ................................................................................ 11

Marine Transmissions ................................................................................................................ 12

Resolving a Service Problem .......................................................................................................13

Crusader Master Distributors .......................................................................................................14

Dealer’s Responsibilities ............................................................................................................ 15

Transferable Warranty ............................................................................................................... 16

Direct Sale By Owner ................................................................................................................ 16

Notes ..................................................................................................................................... 17

2 - BOATING RESPONSIBILITY ............................................................................................. 18-20

Carbon Monoxide Hazard ........................................................................................................... 18

Safe Boating Suggestions .......................................................................................................... 19

Water Wisdom .......................................................................................................................... 19

Operation and Maintenance ........................................................................................................ 19

Rules of the Road ..................................................................................................................... 20

3 - ENGINE IDENTIFICATION ................................................................................................ 21-22

Engine Identiﬁcation .................................................................................................................. 21

Owner Identiﬁcation and Registration Information ............................................................................ 21

2004 Model Identiﬁcation / Advisory ............................................................................................. 22

4 - OPERATING INSTRUCTIONS ........................................................................................... 23-27

Instrumentation .......................................................................................................................... 23

Engine Alarm System ................................................................................................................ 24

Remote Controls ...................................................................................................................... 24

Starting Engine ......................................................................................................................... 25-26

Shifting Transmission ................................................................................................................ 26

Stopping Engine ....................................................................................................................... 27

Freezing Temperature Operation .................................................................................................. 27

Operation in High Debris Areas ................................................................................................... 27

TABLE OF CONTENTS

2L510019-05

TABLE OF CONTENTS

5 - CONDITIONS AFFECTING OPERATION ................................................................................. 28

Trim and Weight Distribution ....................................................................................................... 28

Boat Bottom ............................................................................................................................. 28

Propeller Selection .................................................................................................................... 28

6 - ENGINE BREAK-IN PERIOD ................................................................................................. 29

7 - 25-HOUR ENGINE INSPECTION ............................................................................................ 30

8 - FUEL REQUIREMENTS ................................................................................................... 31-32

Gasoline Requirements .............................................................................................................. 31

Gasoline Containing Alcohol ....................................................................................................... 31

Piston Damage Due To Detonation and/or Pre-Ignition ................................................................................. 32

9 - OIL REQUIREMENTS ........................................................................................................... 33

Engine Oil Recommendations ..................................................................................................... 33

Transmission and “V”-Drive Oil Requirements ................................................................................ 33

10 - ENGINE MAINTENANCE ................................................................................................ 34-54

Engine Maintenance .................................................................................................................. 34

Checking Fluid Levels ........................................................................................................... 34-35

Lubrication .............................................................................................................................. 36

Electrical System Circuit Breaker ................................................................................................. 37

Electrical System Fuse .............................................................................................................. 37

Ignition Fuse ............................................................................................................................ 37

Electrical System Wiring and Connectors ...................................................................................... 37

Battery .................................................................................................................................... 38

Fresh Water Cooling System Sacriﬁcial Zinc Anode ......................................................................... 38

Checking Coolant Level ............................................................................................................. 39

Flushing Cooling System - Sea-Water Section ................................................................................ 39

Testing Coolant For Alkalinity ...................................................................................................... 40

Draining Fresh-Water Cooling System .......................................................................................... 40

Filling Fresh-Water Cooling System .............................................................................................. 41

Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) ....................... 42

Fuel System Description ............................................................................................................ 43

Electric Fuel Pump ......................................................................................................................................... 43

Priming the Fuel System ................................................................................................................................ 43

Flame Arrestor ............................................................................................................................................... 43

Serpentine Drive Belt ................................................................................................................. 43

Changing Oils .......................................................................................................................... 45

Engine Alignment ................................................................................................................. 46-49

Engine Maintenance Log ............................................................................................................ 50

Maintenance Schedule .......................................................................................................... 51-52

Visual Inspection ...................................................................................................................... 53

Engine Fluid Capacities ............................................................................................................. 53

Transmission Fluid Capacities ..................................................................................................... 53

Filter Requirements ................................................................................................................... 54

L510019-05

TABLE OF CONTENTS

11 - ENGINE SPECIFICATIONS ............................................................................................. 55-56

12 - OUT-OF-SEASON STORAGE .......................................................................................... 57-61

Engine Storage ........................................................................................................................ 57

Draining Instructions .................................................................................................................. 58

Battery Storage ........................................................................................................................ 58

Out-Of-Season Engine Warm-Up ................................................................................................. 59

Recommissioning After Storage .............................................................................................. 59-60

13 - TROUBLESHOOTING .................................................................................................... 61-64

14 - WATER FLOW DIAGRAM ................................................................................................... 65

15 - ENGINE HARNESS WIRING DIAGRAMS .......................................................................... 66-67

16 - LITERATURE .................................................................................................................... 68

17 - FORMS ........................................................................................................................ 69-73

18 - NOTES ............................................................................................................................. 75

4L510019-05

SERVICE and WARRANTY - 1

SAFETY INFORMATION

“Safety Warnings” and additional information or

instructions are used to alert the installer/operator of

possible safety hazards in performing certain service

or maintenance procedures incorrectly or carelessly.

DANGERS and WARNINGS are accompanied by the

international HAZARD symbol:

These “Safety Warnings” alone cannot eliminate the

hazards that they signal. Strict compliance with

these warning instructions while performing service

and maintenance procedures, plus “common sense”

operation, are major accident prevention measures.

REPLACEMENT PARTS

Use of replacement parts (i.e. automotive, after-market,

etc.) in the electrical, ignition and fuel systems, which are

not U.S. Coast Guard approved, could cause a ﬁre or

explosion hazard and should be avoided.

Always request that genuine Crusader Marine Engines

replacement parts be used in any repairs or maintenance

being performed on your engine(s).

DANGER

Electrical, ignition and fuel system components are

designed and manufactured to comply with U.S.

Coast Guard rules and regulations to minimize the

possibility of ﬁre or explosion hazard.

DANGER

Signals serious damage, failure or breakdown of equipment; severe injury or high probability of death to the user if

proper precautions are not taken. This signal word is applied in extreme situations

SAFETY WARNINGS

WARNING

Indicates a potential hazard which could result in personal injury.

CAUTION

Indicates a hazard which could result in damage to equipment.

WARRANTY NOTICE: Indicates a possible warranty exclusion.

IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.

L510019-05

SERVICE and WARRANTY - 1

OWNER’S SERVICE

AND

WARRANTY INFORMATION

CRUSADER MARINE ENGINES’ COMMITMENT TO YOU

Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine. Your Dealer also

wants you to be completely satisﬁed, and invites you to return for all your servicing needs, both during and after the

warranty period.

OWNER WARRANTY REGISTRATION

It is important that your selling dealer ﬁll out the “Warranty Registration Card” completely and mail it to the factory

immediately upon the purchase of the new product. It identiﬁes the name and address of the original purchaser, product

model(s) and serial number(s), and the selling dealer’s name and address. The dealer is also certifying that you are

the original purchaser of the product.

Upon receipt of the “Warranty Registration Card” at the factory, you will be issued an “Owner Warranty Registration

Card.” The “Owner Registration Card” is your only valid registration identiﬁcation, and must be presented to the

servicing dealer, should warranty service be required.

If your “Owner Registration Card” is not received within 30 days from the date of purchase, please contact your boat

dealer or engine seller. The product warranty is not effective until the Product is registered at the factory.

Mail registration information to:

NOTE: OWNERS WARRANTY REGISTRATION CARD IS LOCATED AT THE BACK OF THIS MANUAL.

NOTICE: Registration lists must be maintained by the factory and dealer on marine products sold in

the United States and some foreign countries, should notiﬁcation under FEDERAL BOAT SAFETY

ACT be required. It is our desire to have all products registered at the factory, should it ever be

necessary to contact you. Make sure your Dealer/Distributor ﬁlls out the registration card immediately

and sends the card to the factory.

Crusader Marine Engines

P.O. Box 369

Little Mountain, SC 29075

6L510019-05

SERVICE and WARRANTY - 1

ENGINE OPERATION AND CARE

Considering the investment that you have made in your new Crusader engine(s), we know you will want to operate

and maintain it properly. We urge you to follow the maintenance instructions contained in your engine’s “Operation

and Maintenance Manual.”

If you have any questions on how to keep your engine in good working condition, see your selling dealer, the place

where many owners choose to have their maintenance work done. Your dealer can be relied on to use proper parts

and practices.

MAINTENANCE RECORDS

It is recommended that receipts covering the performance of regular maintenance be retained. Damage to your engine,

caused by lack of maintenance, is not covered under your warranty. Receipts can be very important if a question arises

as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship. An “Engine

Maintenance Log” is provided in the MAINTENANCE SCHEDULE section of the OPERATION AND MAINTENANCE

MANUAL for your convenience in recording the service performed.

LOCAL REPAIR SERVICE

To obtain service or make a claim under your warranty, contact your selling dealer. They have trained technicians,

knowledge and special tools and equipment to properly service your engine, if the need arises. They know you and

your boat best.

SERVICE AWAY FROM HOME

If you are away from home and your local dealer, and the need for service arises, contact the nearest authorized

Crusader Marine Engines dealer. Refer to the yellow pages in the telephone directory. If, for any reason, you cannot

obtain service, contact the Crusader Master Distributor closest to you for referral to the nearest authorized servicing

dealer. (Refer to regional map and listing of Crusader Master Distributors on page 14.)

L510019-05

SERVICE and WARRANTY - 1

REPLACEMENT PART INQUIRIES

All inquiries concerning replacement parts should be directed to your local authorized dealer. The dealer has the

necessary information to order parts for you if they are not in stock. Only authorized distributors can purchase parts

from the factory. Crusader Marine Engines does not sell to unauthorized dealers or retail customers. When checking on

parts, the dealer will require the engine model and serial number to order the correct parts.

REPLACEMENT SERVICE PARTS

WARNING

Electrical, ignition and fuel system components on Crusader Marine Engines are designed and manufactured to

comply with U.S. Coast Guard rules and regulations to minimize the risks of ﬁre or explosion. Use of replacement

electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a

ﬁre or explosion hazard and should be avoided.

When servicing the electrical, ignition and fuel systems, it is extremely important that all the components are properly

installed and tightened. If not, any electrical or ignition component opening, if a fuel system leak were to exist, would

permit sparks to ignite fuel vapors from the fuel system leaks.

APPLICABLE LIMITED WARRANTY

Following is the limited warranty applicable to Crusader Marine Engines sold and used in the United States and

Canada.

Distributors and Dealers are not agents of Crusader Marine Engines. Crusader Marine Engines does not authorize any

person to create any other obligation or liability in connection with this product.

8L510019-05

SERVICE and WARRANTY - 1

CRUSADER, INC. INBOARD MARINE ENGINES

ONE YEAR LIMITED WARRANTY

(For Engines Sold and Used in the United States and Canada Only)

1. Crusader, Inc. (hereinafter referred to as “Crusader”) warrants each of its new inboard marine engines an

accessories attached thereto (“Products”), to be free from defects in material and workmanship for a period of

one (1) year, except to the extent limited herein. This Limited Warranty commences on the day of the ﬁrst retail

sale and/or the ﬁrst date used, and extends to the original and subsequent retail sales; however, in no event shall

the duration of the Limited Warranty exceed one (1) year, as measured from the original retail sale date.

2. Under this Limited Warranty, Crusader’s obligation is limited to repairing or replacing those parts of Products that

have become defective within the applicable warranty period, because of defective materials or workmanship.

Crusader will arrange for the correction of all defects under this Limited Warranty to be made free of charge

at the selling dealership or an authorized Crusader service center. Crusader, in its discretion, may provide for

the repair or replacement of any defective part at Crusader’s facility. Crusader will make payment for labor to

replace such parts as provided in the, then, current ﬂat rate labor manual or Warranty Procedures Manual.

3. This Limited Warranty does not apply to Product defects caused by normal wear and tear to Products, and/or

damage to Products arising out of negligence or lack of proper care, improper installation or service, operation

with fuels, oils or lubricants which are not suitable for use with Products, alterations or removal of parts,

water entering an engine through the exhaust system or carburetor, installation of accessories or parts not

manufactured or sold by Crusader, or Products rendered defective by accident.

4. If a part should become defective within the applicable warranty period, advance authorization by Crusader is

necessary before the part is replaced or a defect is corrected by a service representative; otherwise Crusader will

not be liable for the expense of the replacement or correction.

5. Replacement parts and accessories supplied by Crusader, and installed on a Product during the period when

the Product is covered under the provisions of this Limited Warranty, are warranted for the unexpired portion of

the existing warranty period, or ninety (90) days from the date of installation of such new parts or accessories,

whichever is longer.

6. Reasonable access to the Product must be provided for warranty service. This Limited Warranty does not

cover: (1) telephone or telegram charges, towing charges, storage, launch and haul out charges, loss or damage

to personal property, loss of revenue, loss of time, travel, lodging, inconveniences or other CONSEQUENTIAL

DAMAGES, or (2) removal and/or replacement of boat partitions or material, because of boat design, for

necessary access to the Product.

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