Volvo 4.3all - OperatingManual

Owner’s Manual
VOLVO
PENTA
WELCOMEABOARD Our Joint Responsibility
Please study this manual to completely understand how Volvo Penta invests, annually, considerable developmen-
your Volvo Penta stern drive operates and to enable you to tal resources to minimize the effects on the environment
take full advantageof its manybuilt-in features. caused by our products. Examplesof this continuous work
are the improvements in exhaust emissions, sound levels,
Boating Responsibilities and fuel consumption.
Whetheryour Volvo Penta stern drive is used to power a

Most countries have regulations controlling boating. Al-
ways makesure you follow these regulations! As a boat pleasure boat or is usedin a commercialapplication it can, if
used incorrectly or maintained insufficiently, disturb or
owner, you have certain responsibilities to others. Be sure
that all operators read this manual. damage the environment,
Youare legally responsible for all occupantsof your boat. The Operators’s manual covers several service checks
Instruct at least one of your passengersin the basic funda- that, if not performedcorrectly, can causea deterioration of
mentals of handling your boat in case of an emergency. the engine affecting the environment, its service life and
Showall hands the location of emergencyequipment and operating economy. Always follow the recommendedserv-
howto use it. In the U.S. you are required by law to haveone ice intervals and makeit a habit to check for anything
U.S. Coast Guard approved life jacket for each person abnormal each time you use the engine. An exampleof this
3857730 - Downloaded from www.volvopenta.com 11/11/2010 09:38:03
aboard, plus one approved throwable device for man over- is excessive exhaust smoke.Contact a Volvo Penta dealer if
board protection. you cannot remedy the cause yourself.
Learn the waterwayrules of the locality in which you are Remember that most chemical products used to maintain
going to operate your boat. Navigable waterways are con- your boat and engine are harmful to the environment, if
trolled by Federal regulations while inland lakes are con- used incorrectly. Alwayscorrectly dispose of used motor oil,
trolled by local jurisdictions. Obeythese regulations to vertical drive lubricant, paint, degreasingagents and wash-
protect yourself, your passengersand fellow boating enthu- ing fluids, etc., so that they cannot harm the environment.
siasts.
When using your boat, always adjust the speed and
distance to prevent the wakeor sound level from disturbing
Thoroughly familiarize yourself with weather bureau
wildlife, mooredboats, pontoons, etc. Leave the waters and
warning system signals and waterwaytraffic signs. natural harbors in the condition you yourself would like to
find them.
In the U.S. contact your local U.S. Coast Guardstation and
take advantageof their seasonalboat inspections and train-
ing courses. Wethank you for your choice of Volvo Penta stern drive
and we wish to continue to supply you with maintenance
and advice to help you get the best possible performance
from your stern drive. Contact your nearest Volvo Penta
dealer if assistance is required.
Wewish you pleasant trips with your boat.
AB VOLVO PENTA
Identification Numbers
Record your engine, transom shield and drive unit model and serial numbersimmediately after purchase. This will
enable you to have themavailable for quick reference whenordering parts or literature.
Engine Model No. Serial No.
Transom Shield Model No. Serial No.
Drive Unit Model No. Serial No.
Ignition Key No. RecommendedPropeller Size
Boat Model No. Hull Identification No. (HIN)

Read this manual carefully before attempting to operate your engine.
GENERAL INFORMATION FEATURES
;FUEL AND LUBRICATION STARTING AND OPERATION

Lr?====,~
SPECIFICATIONS AND MAINTENANCE
_J
LO
L9
THIS PRODUCT MAY BE SERVICED BY ANY AUTHORIZED

OMC STERN DRIVE OR VOLVO PENTA SERVICING DEALER.
CV -9825/eng Printed in the U.S.A.

4 BCD
GENERAL INFORMATION
Basic Safety Rules of Boating .................. 3 Repair Service .............................. 3

Boater’s Responsibilities ...................... 3 Safety .................................... 2
Illustration Symbols .......................... 2 Stolen Unit ................................. 2
Model and Serial Numbers .................... 3 Symbols ................................... 4
Owner’s Identification Card .................... 2 Technical Literature .......................... 2
Product References,Illustrations and Specifications . 2 Toll Free Dealer Locater Service ................ 3
SAFETY Recordeach of these numbersin the spaces provided on

the inside front cover of this manualandon a separatesheet
This manualcontains certain information related to the of paper. Store the separate sheet of paper in a safe place
personal safety of you the operator, your passengersand other than your boat.
bystanders.
In case of theft, report the modeland seriam numbersto
The Safety symbolA~ , appearsnext to important infor- your local authorities, your insurance agent, and Volvo
mation to prevent you and others from being hurt. Penta.
The Note symbol [~E], appears next to important OWNER’S IDENTIFICATION CARD
information to keep machinery from being damaged.
Whenyou purchased your boat, the dealer wasrequired

Observeall notes and safety warningscontained in this to completea warranty and registration form for your Volvo
manual. Penta sterndrive. The owner’s portion of this form is your
Owner’s Identification Card. This card provides proof of
PRODUCT REFERENCES, ILLUSTRATIONS AND ownership and is required to validate warranty, should
SPECIFICATIONS warranty service be necessary. Warranty coverage maybe
withhelduntil the warrantyandregistration formis or= file at
Whenreference is madein this manualto a brand name, Volvo Penta.
number,product or specific tool, an equivalent product may
be used in place of the product referred to unless specifi- TECHNICAL LITERATURE
cally stated otherwise. Equivalent products which are used
must meet all current U.S. Coast GuardSafety Regulations VolvoPentaoffers technical literature written specifically
and ABYCstandards to avoid hazards. for your motor. A service manual, a parts catalog, or an
extra operator’s manualcan be purchasedfrom your Volvo
All information, illustrations and specifications contained Pentadealer.
in this manualare basedon the latest product information
available at the time of printing. VolvoPentaMarineProd- This manualis intended for use in the U.S. and Canadian
ucts LP reserves the right to makechangesat any time, markets only.
without notice, in specifications andmodelsandalso to
discontinuemodels.Theright is also reservedto change For the nameand location of the nearest Volvo Penta
any specifications or parts at any time without incurring dealer, in the U.S consult the Yellow Pagesunder "Boat
any obligation to equip sameon modelsmanufactured Dealers" or call 1-800-522-1959.
prior to date of suchchange.
ILLUSTRATION SYMBOLS
Thecontinuing accuracyof this manualcannotbe guaran-
teed.
Refer to the photoor drawing
All illustrations usedin this manualmaynot depict actual describedby that paragraph.
models or equipment and are intended as representative Referto specific itemsor features
views for reference only.
@®@ describedin the text andillustrated
in the photo.
STOLEN UNIT
The model and serial numberson your engine, transom Referto the generalsubjectof the text.
shield, anddrive unit are important to you. For locations of
these important numbers, refer to Model andSerial Num- Referto an itemor featurethat is not
bersin this section. .,~’~ clearly visible in the photo.
CV-9825/eng
DR4282 DR2058 DR4g~7
GENERAL INFORMATION
BOATER’S RESPONSIBILITIES MODEL AND SERIAL NUMBERS
Theoperator is responsible for the correct operation of [~ The primary mode~and serial numbersare located on
the boat and for the safety of its occupants.Makesure that the engine as illustrated. Thesenumbersare required for
all operators read this manualbefore operating the boat. warranty registration, warrantyservice, and ordering parts.
Showyour passengers the location of emergencyequip Theyare also referred to as enginemodeland serial number
men’I and explain how to use it. Be sure one of your becauseof their location. Thesticker on the bottomof this
passengers knows how to handle your boat in case of tag shows the drive unit and transom shield model and
emergency.Requirementsfor personal flotation devices serial numbers.

and other safety equipmentvary dependingon the type of
boat.. Alwayscomplywith the regulations that apply to your ~] The model and serial numbersof the transom shield
boat. are located on the inner transomshield plate as illustrated.
[~ The model and serial numbersfor the drive unit are

BASIC SAFETY RULES OF BOATING locatedon the drive unit behindthe port trim/tilt cylinder as
illustrated. Thesenumbers are usedto identify the drive unit
O Shut off engine whenthe boat is near people who and to matchit with the engine.
are in the water.
@ Avoid standing up or shifting weight suddenly in REPAIR SERVICE
small, lightweight boats.
Alwaystake your Volvo Pentasterndrive to an authorized
O Keepyour passengersseated in seats. The boat’s Volvo Pentaservicing dealer. Hehas the knowledge,factory
bow, gunwale, transom, and seat backs are not trained technicians and special tools to take care of prob-
intendedfor use as seats. lems that mayarise. Preferably take your Volvo Penta
¯ insist on the useof life preserversby all passengers sterndrive back to the selling dealer - he also knowsyou
when boating conditions are hazardous, and by and your equipment.
children and non-swimmers at all times. m
e Knowthe marine traffic laws and obey them.
Toll Free Dealer Locator Service
¯ Preventexplosionand fire by maintainingyour fuel
delivery system in top condition. Fuel vapor is If you are awayfrom your homewaters, take your
volatile; handlefuel with care. Volvo Pentasterndrive to the nearest authorized Volvo
¯ Keep your boat and equipment neat and in top Penta servicing dealer. To locate an authorized Volvo
operatingcondition. Carry a selection of spareparts Pentaservicing dealer, consult the Yellow Pagesunder
for the engine. "Boat Dealers" or call 1-800-522-1959.
¯ DON’T OPERATEBOAT IF YOU ARE UNDERTHE
INFLUENCEOF DRUGSOR ALCOHOL.
¯ If boating waters are unknown,obtain navigational
and bottom charts to avoid damagefrom underwa-
ter objects.
CV-9825/eng 3
GENERALINFORMATION
SYMBOLS
Certainsymbolsor combinations
of symbols
mayappearon yourVolvoPentasterndriveor on its accessories.It is very
importantthat youunderstand
their meaning
or purpose.If anysymbolis not clearly understood,seeyour VolvoPenta
dealer.
"Safety Warning" Symbols
Fire hazard
Contents under pressure

"Position Indicator" Symbols
Shift positions
NEUTRAL
RAISE
~ LOWER
FORWARD
I"-o
REVERSE
"Condition" Symbols
E
¯ Voltmeter
Hour meter ,~ o Ammeter Tachometer
Voltmeter (~ Fuel filter

Oil filter
Water temperatu re A Emergency stop Oil pressure
"instructional" Symbols
~,~ o Use gasoline

¯ Gasoline is present ~ Read Operator’s Manual
before operating product Oil fill
DR3847
CV-9825/eng
FEATURES
Circuit Breakers and Fuses ..................... 9 Power Trim/Tilt .............................. 5

DuoProp®Drive Unit, Rotation and Propellers ..... 10 Propellers ................................. 10
Emergency Stop Switch ....................... 8 Sacrificial Anodes ........................... 9
Impact Protection ............................ 5 Steering ................................... 5
Instruments ................................ 8 SX Drive Unit, Rotation and Propellers .......... 10
Engine Feature Identification ................... 6
POWERTRIM/TILT IMPACT PROTECTION
Your Volvo Penta sterndrive is equipped with a power The trim/tilt system provides impact protection for the
trim/tilt system as standard equipment. The purpose of drive unit. Stiml, impact damagecan occur in either FOR-
power’trim/tilt is to enablethe operatorto changethe angle WARD or REVERSE directions. Care must be taken:
of the drive unit from the helm. Changingthe angle of the
drive unit in relation to the boat bottom is called "trim- ¯ Whenoperating in FORWARD or REVERSE
ming." Trimmingprovides the following benefits:
¯ Whentrailering boat
¯ Improvesacceleration onto plane
¯ Whenlaunching boat
,J Maintainsboat on plane at reducedthrottle settings

Impact damage is morelikely to occur whenin a turn where
,i Increases fuel economy side loads are placedoil the drive unit.
.DProvidessmootherand/or drier ride in choppywater If the drive unit strikes a solid object, throttle backand
conditions shut off engine immediately. Closely inspect the boat and
drive unit for damage,particularly the transomshield as-
~DIncreases top speed sembly that contains steering system components.Check
engine compartmentfor water leakage.
If you do not wish to use this feature, you mayleave the
drive unit trimmedto the position that worksbest for your if there is obvious or suspecteddamage,operate boat at
normal boating. low RPMand take your boat to a Volvo Penta dealer for
inspection. Have necessary repairs madeimmediately.
STEERING Operating a damageddrive unit could cause additional
damageand could becomevery costly to repair.
Volvo Pentasterndrives feature a powerassisted steering
system. It consists of an engine mountedpump,hoses, and Z~ Safety Warning:Fai|ure to inspect for damage
may:
steering cylinder. Thesework in conjunction with the helm
and steering cable to movethe tiller arm, thus movingthe ¯ Resultin sudden loss of steeringcontrol.
drive unit. ¯ Adversely
affect yourboatanddrive unit’s ability to
resist subsequent high speedimpacts.
Whenmovingin REVERSE
there is no impact protec-
tion. Use CAUTIONwhen moving in REVERSE.DO NOT
EXCEED 2500 RPM.
CV-g825/e ~g 5
FEATURESB
® ®
® @
| /
45997
item Description Page j kem Description Page

1 Alternator. 23 I 14 Model & Serial Number, TransomShield 3
2 Anodes(Sacrificial) 9,38 15 Model & Serial Number,Drive Unit ..... 3
3 Backfire FlameArrestor 26 j 16 Motor Oil Fill Cap ................... 3t
4 Carburetor 27 17 Oil Filter .......................... 31 I
5 Circuit Breakers 9,25 18 Oil Withdrawal Tube ................. 31 I
6 Drain (Engine) 30 = 19 J PowerSteeringPump ................ 13 I
7 Drain (Manifold). 30 20 Steering Cable ..................... 13 [
8 Drive Oil Level Dipstick 32,35 21 Trim/Tilt Reservoir Cap ............... 13 I
9 EngineOil Level Dipstick 31 22 Trim/Tilt PumpAssembly ............. 13 I
10 FuelFilter. 26 ; 23 Pivot Housing Water Drain Plug ........ 30
11 Fuel Pump(Electric). 26 i 24 ] Water Intake ....................... 29
12 GimbalBearing Lube Fitting 33,36 25 I Water Supply Pump................. 30
13 Model & Serial Number,Engine 3 26 9,25 J
I Trim/Tilt Fuse ......................
CV-9825/eng
C,4.9B2~5/emg
/
/
7
36416
FEATURES
iNSTRUMENTS Usingthis switch is simple and should not interfere with

normal operation of the boat. Care must be taken to avoid
Before operating your Volvo Pentasterndrive, familiarize accidentally pulling the lanyard during normal operation.
yourself with the instruments supplied with your boat. Unexpectedloss of forward motion witt occur. This could
Someboats maynot have Volvo Penta instruments, read the allow occupants to be thrown forward. In an emergency
boat’s owner’s manualto familiarize yourself with the in- situation, any occupantof the boat can restart the engine.
struments used. Just press in and hold the emergencystop switch button,
then follow normal starting procedure. Whenthe button is
Volvo Penta Instruments released, the enginewill stop.
(~ PowerTrim/Till Gauge- Indicates whetherthe boat is Z~ Safety Warning: The emergencystop switch can only
trimmed to a "Bow-Up" ~ or "Bow-Down"~ condition. be effective whenin good working condition. Observethe
following:
(~ Tachometer- indicates the engine RPM.
© Speedometer- indicates boat speed MPH~ ¯ Lanyardmust aiwa~/s be free of entanglementsthat
could hinder its operation.
@Voltmeter - With ignition on, engine not running, the
voltmeter indicates battery voltage. With engine running, e Oncea month, check switch for proper operation.
the voltmeter indicates alternator voltage output. With engine running, pull lanyard, if engine does
® Oil PressureGauge- Indicates engine oil pressure. not stop, see your dealer.
® Water TemperatureGauge- indicates water tempera- Z~ Safety Warning: If your boat is not equipped with an
ture in the engine’s cooling system. emergencystop switch and it fails into one of the following
categories, installation of an emergencystop switch is
Other Instruments recommended.
Seeyour Volvo Penta dealer for additional Volvo Penta ¯ High performancesport boats
accessories specifically designed for your Volvo Penta
sterndriveo ¯ Small runabouts
EMERGENCY
STOP SWITCH ¯ Boats with sensitive steering
~’] An emergencystop switch (~ maybe a feature of your ¯ Boats where the distance from the top of the
Volvo Penta sterndrive poweredboat. Useof this switch is gunwaledownto the driver’s seat is less than 12 in.
highly recommended. To properly use this feature, attach (30,5¢m).
the lanyard ® securely to your clothing. Donot attach the
lanyardto clothing that will tear awaybefore the lanyardis Seeyour Volvo Pentadealer for installation of an emer-
pulled from switch to stop the engine. If the lanyard is too gency stop switch.
long, shorten the lanyard by knotting or looping it. DONOT
cut andretie the lanyard.
CV-9825/eng
372S0A
FEATURES
SACRIFICIALANODES Boats that connect to an ACpowersource (shore power)

require protection against galvanic and "stray current"
]~] ~D Sacrificial anodesare attached to the bottom of corrosion.For protection, a galvanic isolator canbe installed
the girnbal housing O, and at the front of the gearcase in the grounding (green) wire betweenthe boat and the
above the anti-ventilation plate (~. Anodesare slowly shore poweroutlet on the dock. The isolator blocks direct
eroded away by galvanic action and require inspection. current (DC) flow, but permits the passageof alternating
Anodessubjected to frequent wetting and drying require current (AC) thereby providing a path for ground fault
periodic scraping to removescale and oxidation to maintain currents.
their effectiveness.
If a boat is connectedto an ACpowersource (shore
Whenreplacement is required, see your Volvo Penta power) and it is not equippedwith a galvanic isolator,
dealer. The material composition of Volvo Penta anodes additional sacrificial anodesmaybe required to handlethe
meets UoS.Military Specification 18001-H.If other than addedcorrosion potential.
Volvo Penta anodesare used, makesure they have equiva-
lent specifications or gaJvaniccorrosion protection will be [~ ~ Whenthe boat is primarily used in a fresh water
lost. if additional electronic or electrical equipmentis in- environment, Volvo Penta recommends replacing the zinc
stalled; each should have an individual anodeor grounding anode 0 with a magnesiumanode.
device and all grounding devices must be interconnected.
Follow equipment manufacturer’s recommendations. CIRCUIT BREAKERS AND FUSES
[~ inspect gimbal housing and front gearcase anodes The engine and boat’s electrical system is protected by
every 14 days, or morefrequently if used in extremelysalty circuit breakers and fuses against current overload. If a
water.If an anodeis ~/3 its original size (V3eroded),it should circuit breakertrips, it canbe reset by pushingits button. A
be replaced,if a stainless steel propeller is used,additional blownfuse must be replaced. Circuit breakersor fuses that
sacrificial anodesmaybe required to handle the added repeatedly fail indicate a problem requiring immediate
corrosionpotential. attention. Seeyour Volvo Pentadealer.
CV-9825.,er=g 9
DRZ031A DR202S DP,2030
FEATURES
SX DRIVE UNIT, ROTATION AND PROPELLERS Neverinterchangea right-hand propeller with a left-
hand propeller. This would result in the boat being pro-
Twin Engines pelled in reverse whenthe motors are operated in forward
gear, and forward whenmotors are operated in reverse
Your Volvo Penta sterndrive can be set up to rotate in gear. To help you better understandand tell the difference
either direction. Thepropeller, propeller shaft and vertical betweenleft- and right-hand propellers, see illustrations.
driveshaft are the only parts that counter-rotate. Theengine
always has standardrotation. After having the propellers serviced, shift into FORWARD
or REVERSE at idle speedand determine if the boat moves

J~ Twin engine installations should have the starboard in the direction indicated by the position of the control
drive unit set up for right-hand propshaft rotation (standard handle. If the boat movesOPPOSITE the direction indicated
rotation) and the port drive unit set up for left-hand prop- by control handle, the propellers are switched.
shaft rotation (counter-rotation). Propeller rotation is as
viewedfrom the rear. Safety Warning:Failure to performthe abovetest could
result in lossof control.
Some boat manufacturers may set up twin
sterndrives just the opposite. Whenpropellers and/or drive DUOPROP ~ DRIVE UNIT, ROTATION AND
units are removed,care mustbe takento attach the shift link PROPELLERS
in the sameeccentric position it wasin whenremovedand
that the propellers are not switched. DuoPropdrive units have counter-rotating propellers and
it is not necessaryto changedrive unit rotation. Thepropel-
Single Engines lers operatein sets. Theforward propeller is left-hand and
rotates counter-clockwise.Therear propeller is right-hand
All single engineinstallations are set up standard-rotation and rotates clockwise.
and use right-hand propellers.
PROPELLERS
Propellers
Your Volvo Penta sterndrive should be equipped with
[] Right-handpropellers rotate clockwise to propel a boat propeller(s) that are designedto give top performanceand
forward. Right-hand propellers are considered standard- maximum economy under all operation conditions. To ob-
rotation propellers. To identify a right-handpropeller, note tain peak performance, the engine RPMAT FULLTHROTTLE
the angle ® of the blade as viewedfrom the port side. must fall in the specified operating range at normal load
IT] Left-hand propellers rotate counterclockwiseto propel conditionsat favorable/besttrim settings.
a boat forward. Left-hand propellers are consideredcoun- if full throttle RPMis belowthe recommended operating
ter-rotation propellers. Toidentify a left-hand propeller, note range, propeller(s) with less pitch should be used. Should
the angle ® of the blade as viewedfrom the port side. full throttle RPMexceed the recommended range, install
¯ A drive unit set up for standard rotation must be propeller(s) of higher pitch. Selecting the correct propel-
ler(s) to allow the engine to run at full throttle in the
equippedwith a standardrotation (right-hand) pro- recommended operating range will give the best enginelife,
peiler. fuel economy, and performance. See your Volvo Penta
e A drive unit set up for counter-rotation must be dealer for help in determiningthe correct propeller(s) for
your application.
equippedwith a counter-rotstion (left-hand) propel-
ler. A damagedpropeller must be changedwithout de-
lay. Operatewith extremecaution if a propeller is dam-
aged. Do not operate DPmodelswith only one propeller,
this can causedamage to propellor shafts.
0 CV-9825/eng
FUEL AND LUBRICATION
Drive Unit Lubrication ....................... 13 Oil Identification Symbol..................... 12

Engine and Drive Service ..................... 12 Power Steering Fluid Level .................... 13
Gasoline Containing Alcohol .................. 11 PowerTrim/Tilt Fluid Level .................... 13
Gasoline Requirements ...................... 11 SAEViscosity Chart ......................... 12
Gimbal Bearing Lubrication ................... 13 Steering System Lubrication .................. 13
Mo:tor Oil ................................. 12
GASOLINE REQUIREMENTS To prevent gum formation and corrosion in the fuel

system,frequently use a fuel stabilizer in the gasoline. Fuel
USE ONLY UNLEADEDFUEL stabilizer is available from your VolvoPentadealer.
Z~ S~fety Warning: Gasoline is extremely flammableand GASOLINES CONTAINING ALCOHOL
highly explosive under certain conditions. Always stop
engin,s and do not smokeor allow openflames or sparks Manygasolines being sold today contain alcohol. Two
near the boat whenrefueling gas tanks. commonlyused alcohol additives are Ethanol (ethyl alcohol)
and Methanol(methyl alcohol).
/~ Safety Warning:When filling the gas tank, groundthe
tank to the sourceof gasoline by holdingthe hosenozzle Seeyour operator’s manualfor your boat to determineif
firmly againstthe side of thedeckfiller plate or groundit in the boat’s fuel system is compatible with alcohol blended
someother manner.This action prevents static electricity fuels. If it is compatible,your enginemaybe operatedusing
build-’.up whichcouldcausesparksandignite fuel vapors. gasolines blended with no morethan 10%Ethanol meeting
the minimumoctane specification. Do not use any gasoline
Maximumperformance requires the use of lead-free which contains METHANOL.
gasoline with the following minimumor higher octane
specification: Serious damage
will result from the continued use of
fuel containing METHANOL.
Inside the U.S.: (R+M)/2(AKI)
Out;;ide the U.S.: (RON)- If you use gasoline containing ethanol, be awareof the
following:
[~ Use of gasoline with lower than 89 AKI (93 RON)
octanewithout resetting ignition timing as specified, will ¯ Theenginewill operate leaner with ethanol blended
result in serious damage to your engine and will void your fuel. This maycause engine problemssuch as vapor
engine warranty. lock, low speedstall, or hardstarting.
If fuels with 89 AKi (93 RON)octane or higher are not ¯ Ethanol blended fuels attract and hold moisture.
available, the ignition timing will have to be retarded so Moisture inside fuel tanks can cause corrosion of
lower octane fuels, with minimum87 AKI (90 RON)octane, the tank material. Inspect fuel tanks at least annu-
can be used. Seeyour authorizedVolvo Pentadealer for this ally. Replacefuel tanksif inspectionindicates leak-
adjustment. Whenignition timing is retarded, a slight de- age or corrosion.
crease in power can be expected.
¯ Inspect nonmetallic parts of fuet systemfrequently
[~ Engine damageresulting from the use of a lower and replace if excessivestiffness, deterioration or
octane gasoline than 87 AKI (90 RON)is consideredmisuse fuel leakageis found.
of the engineand witl void your enginewarranty.
Z~ Safety Warning:Fuel leakage can contribute to a fire
Detonation or spark knock in a marine engine is not and/or explosion.
necessarily audible. Overheating and continued running
(dieseling) after ignition shut off are indications of detona-
tion in a marineengine. If you suspectdetonation or spark
knock, and the engineis properly tuned, changeto a higher
octanefuel.
cv-ge2s~,g 11
iKKHKHKaHM~H ....+’+~ IIIQ6il’
~ m~..... +,,.+ gl-UiD
DR¢68~ DR1563 DRC6833
FUELANDLUBRICATION
ENGINEANDDRIVESERVICE SAEVISCOSITYCHART
If you chooseto lubricate your Volvo Penta sterndrive LOWEST RECOMMENDED
yourself, refer to the LubricationandInspectionChart in ANTICIPATED SAE VISCOSITYOiLS
Specifications andMaintenancesection for lubrication TEMPERATURE
points and recommended lubricants. Useonly Volvo Penta
recommended lubricants or lubricants of equivalent quality 32° F (0° C) and above SAE30~
and viscosity. See your Volvo Penta dealer for recom- SAE 20W/50
mendedlubricants. SAE 15W/50
0° F (-18° C) to 32° F (0° C) SAE 20W-20
If you chooseto have your Volvo Pentasterndrive lubri-
cated, see your local Volvo Penta dealer. He will gladly Below0° F (-18° C) SAE 10W
lubricate it at the requiredintervals.
¯ SAE30 Volvo Penta DuraPlus" Synthetic Motor Oil
MOTOROIL P/N 3851230-7(U.S and CanadaOnly)
To obtain the best engine performanceand engine life, Usesingle viscosity oils in marketswhereaveilabne.
Volvo Penta DuraPlus" Premiumengine oil labeled for The use of muZti-viscosity oils such as 10W-30,10W-40is
Service CE/SGis recommended, or you must use motor oils not recommended.
with the recommended quality and viscosity. Motor oils are
specified by API service, letter designationsandSAEviscos- At the end of the break-in period (20 hours), changethe
ity numbers.Refer to oil identification symbolon the con- crankcaseoil and replacethe oil filter. Referto Lubrication
tainer. and inspection Chart in Specifications and Maintenance
section for recommended oil changeintervals.
Initial factory fill is a highquality motoroil for APIService
CE/SG.During the break-in period (20 hours), frequently OiL IDENTORCATION SYMBOL
check the oil level. Somewhat higher oil consumptionis
normaluntil piston rings are seated.Theoil level shouldbe Motoroils are specified by APt service letter (CE/SG),and
maintainedbetweenthe Addand Full markson the dipstick. SAEviscosity numbers (SAE 30, SAE20W-20, SAE10W).
The space betweenthe marks represents approximately 1 Thesemaybe foundon the label, top of can, or oil identifica-
quart (1 liter). For oil level dipstick location, refer to the tion symbol.
Featuressection.
[~ Label: Motor Oil
Whenyou add or change motor oil, use Volvo Penta
engineoils for gasoline engines,or a goodquality oil (APi DE] oil Identification Symbol
Service CE/SGor better) of the sameviscosity that meets
General Motors Specification GM-8094-M. Usethe follow- ~’) Label: Gear Lube
ing chart to select the SAEviscosity that matchesthe
temperaturerange in which you expect to operate. [~ Disregard eny reference to multi-viscosity oils
printed on engine.Suchreferenceis intendedfor automo-
SeeSpecificationsandMaintenance section for oil filter tive useonly, andnot for marine8pplication.
type and service intervals.
2 CV-982~eng
43356 33965
47564
FUEL AND LUBRICATION
POWERTRIM/TILT FLUID LEVEL POWERSTEERING FLUID LEVEL
~] Tl~e trim/tilt assemblycontains an electric motor, hy- r~ Wheneveryou check the engine oil level, also remove
draulic pump, and reservoir. At the beginning of each the powersteering oil film capandcheckthe fluid level. Wipe
boating season, check the fluid level in the reservoir as dipstick and note the "HOT"and "COLD"fluid level,,;.
follows: Maintain the appropriate level with Volvo Penta DuraPlus"
powersteering fluid available from your VolvoPentadealer.
Approvedpowersteering fluids such as GMpower steering
~ Level should be between the "MIN" and "MAX"

markson the reservoir. fluid or Dexronfl automatictransmission fluid can also be
used. Donot overfill the pumpreservoir.
¯ If necessary, add Volvo Penta DuraPlus~" Power
Trim/Tilt and Steering Fluid. Replacethe cap (~ and STEERING SYSTEM LUBRICATION
tighten securely.
[~ Every 60 days, grease the steering ram ~) with Volvo
When checkingfluid level, inspect the trim/tilt unit for Penta dense water resistant grease as specified in the
leaks and properoperation, if service is necessary,see your Lubrication and inspection Chart in Specifications and
VolvoPentadealer. Maintenancesection.
DRIVE UNIT LUBRICATION
Thedrive unit is filled at the factory with Volvo Penta

DuraPlus" GL 5 Synthetic Gear Lube. See Specifications
andMaintenancesection for SXand DPdrive unit gear lube
capacity, and draining and filling procedures.
GIMBAL BEARING LUBRICATION
SeeExternal Lubrication Points in Specifications and Main-

tenance section.
STARTING AND OPERATION
Before Starting ............................. 15 Preparation for Boating After Storage ........... 14

Bottom Painting ............................ 22 Propeller Selection .......................... 22
Determining the Proper Trim .................. 19 Pumping Bilge ............................. 18
Engine Break-in ............................ 17 RemoteControl Operating Instructions .......... 14
High Altitude Operation ...................... 21 Salt Water Operation ........................ 20
Howto Shift and Control Speed ............... 16 Shallow Water Operation ..................... 21
Operation After Break-In ..................... 18 Starting Cold Engine ........................ 16
Operating in "Bow-Down"Position ............. 19 Starting WarmEngine ....................... 16
Operating in "Bow-Up" Position ............... 19 Steering System ............................ 21
Operating Procedure for Freezing Temperatures... 21 Stopping Engine ........................... 17
Power Tilt Operation ........................ 20 Trailering Your Boat ......................... 20
Power Trim Operation ....................... 18 Twin Unit Maneuvering ...................... 21
PowerTrim/Tilt Switch and GaugeLocation ....... 18 Twin Unit Steering .......................... 21
PowerTrim/Tilt Switch Operation ............... 18
PREPARATION FOR BOATING AFTER STORAGE _ Your boat maybe equipped with remote controls other
than those described above. If Volvo Pentacontrols are not
1. Replaceall drain plugs. Replacerubber caps and clamps used, ask your selling dealer for operating instructions for
or plugs. Connect hoses and check condition; tighten the remote control used in your boat since operation and
clampsand connections.Install boat drain plug, if removed. function maydiffer from Volvo Penta remotecontrols.
2. Remove distributor cap and rotor. Wipeinside of distribu- r~ Volvo Penta controls have the following important
tor cap dry with a clean cloth and spray with Volvo Penta features:
anti-corrosion spray or equivalent. Replacerotor and cap.
A single lever, which allows you to select FORWARD
3. Clean battery terminals and check battery charge. With or REVERSE gear, regulate engine speed, and en-
ignition switch in OFFposition, install battery and attach sure shifting is doneat low enginespeed.
battery cables. Sprayterminals with Volvo Pentaanti-corro-
sion spray or equivalent. ¯ A start-in-neutral-only feature, which prevents you
from starting your Volvo Pentasterndrive in gear.
4. Openfuel shut-off valve, if so equipped,andcheckall fuel
line connectionsfor leaks. Checkflame arrestor and clean if ¯ Concealed side mountcontrols havea neutral lock
necessary. button ~) to prevent accidental shifting. It must be
squeezedto permit shifting from NEUTRAL to FOR-
5. Makea thorough check of boat and engine for loose or WARD or REVERSE. The binnacle mountcontrols do
missing nuts and screws. Pumpbilge dry and air out engine not havea neutral lock, but do havea neutral detent.
compartment.Federal, state or local regunationsprohibit
the pumping of oil into any navigablewaters° Z~ Safety Warning:Your boat shouldbe equippedby the
manufacturerwith a remote control with protection to
6. Check,and fill as necessary,all reservoir oil levels. prevent starting in gear. Useonly a remotecontrol unit
with start-in-neutral-only feature, This feature canprevent
REMOTECONTROL OPERATINGINSTRUCTIONS_ injury resulting fromunexpectedturning of the propeller
and suddenmovement of the boat.
Familiarize yourself with remotecontrol operation before
starting engine. The shift mechanism on all Volvo Penta controls can be
disengagedto allow for easier starting and engine warm-up.
Your boat may be equipped with one of the following
Volvo Penta remotecontrols: E~ ConcealedSide MountControl
¯ Single lever concealed side mount or binnacle ¯ To disengageshift mechanism:
mountcontrol.
1. Place control handle in NEUTRAL
position ~).
¯ Dual engine dual lever binnacle mountcontrol.
4 CV-9825/eng
DR2891
2. Pressboth neutral lock button ~) and shift disen- Z~ Safety Warning:To prevent a possible explosion, oper-
gage button ©. ate the blower as recommended by the boat manufacturer

before starting engine. If the engine compartmentis not
3. Movecontrol handle FORWARD
to increase throt- equippedwith a blower, openengine cover or hatch prior to
tle. starting to allow any gasoline fumesthat maybe present to
disperse.Leavehatchopenuntil after engine is running.
The neutral lock and shift mechanism
will automatically
engage whenthe control handle is returned to NEUTRAL 1. Operatethe boat’s bilge blower. Frequentlycheckboa’£s
position. bilge area for gasoline fumes.
Binn=¢le MountControl 2. Checkthe bilge for excessivewater accumulation.Always

keepthe bilge clean and dry. Neverallow the water depthin
¯ To disengage shift mechanism: the bilge to exceed the bottom of the engine. If water
accumulationis unavoidable, install a bilge pumpwith an
1. Pushin and hold shift disengagement
button. automatic control switch.
2. Movecontrol handle FORWARD

to increase throt- Thewater level in the boat’s bilge will increasewhen
tle. the boat is operatedat a high incline before planing speedis
reached. Excessive water in the bilge can cause engine
[~ The shift mechanismwill automatically engage when damage.
the control handle is returned to NEUTRAL.
3. Checkenginecrankcaseoil level.
@ Shift MechanismEngaged
® Shift MechanismDisengaged 4. Lowerthe drive unit andmakesure the waterintakes are
(~ ReverseShift Range submerged.
(~ ReverseThrottle Range
® Forward Shift Range Do not start engine out of water unless using a
0 Forward Throttle Range flushing adaptor. Always turn water on before starting
engine. Control water pressure as full water pressure may
BEFORE STARTING cause damageto water pumpand engine. Water pumpwill
be damagedand engine will overheat if operated without
Familiarize yourself with the operation of the remote cooling water.
control supplied with your boat, then proceedas follows.
Z~ Safety Warning:Whenusing a flushing adaptor, re-
movethe propeller before starting engine to prevent acci-
dental contact with movingpropeller. If propeller is not
removed, personal injury could result.
STARTING COLD ENGINE HOW TO SHIFT AND CONTROL SPEED
1. The engine mayrequire priming prior to starting. To If your boat is equipped with a non-Volvo Penta
prime the engine, proceedas follows: remote control system, ask your dealer how to properly
operateit.
¯ Place ignition switch in the OFFposition.
¯ Disengageshift mechanism. Z~ Safety Warning:Carefully checkfunction of all control
¯ Movecontrol handleto the full throttle position; this and enginesystemsbefore leaving the dock.
operates accelerator pumpand primes the engine.
e Repeatpriming, if necessary. 1. Movecontrol handle to the NEUTRAL detent (idle) posi-
e Returnthe control handleto fast idle position. tion. This will engageneutral start switch and allow engine
to start. Checkin front and behindboat for people or
2. Turn key switch to START position and hold until engine obstructionsbeforeshifting.
starts. Do not hold in STARTposition for more than ten
seconds. In colder weather, more priming maybe neces- 2. To go FORWARD - Actuate the neutral lock mechanism
sary. However, too muchpriming mayflood engine. and briskly movethe shift handle forward. Throttle move-
mentwill begin after forward gear engagement.
if EngineFloods:
3. To go in REVERSE - Actuate the neutral lock mechanism
e Disengageshift. Movehandle to full throttle posi- and briskly movethe shift handle rearward. Throttle move-
tion. mentwill begin after reverse gear engagement.
e Turn key switch to the START position,
e Immediately movethe control handle to the idle Donot shift if engine speedis above800 RPM.
position whenthe engine starts.
Z~I Safety Warning: Do not shift from FORWARD to RE-
Failure to movethe control handleto the idle position VERSE whenboat is planing.
immediately whenengine starts will allow engine to over-
speed and engine damagecould result. Over speeding 4. To go from FORWARD to REVERSE,or REVERSEto
engine after off-season storage could also damagethe FORWARD, always pause at NEUTRALand allow engine
water pumpimpeller. Whenstarting enginefor the first speedto return to idle.
time after off-seasonstorage, alwaysidle enginefor one
minuteto allow the water pumpto prime. 5. After shifting is completed,continue to movethe control
handle slowly in the desired direction to increase speed.
3. As soonas engine starts:
/~ Safety Warning: Any time the boat is operated, be
¯ Release key to the ONor RUNposition. aware of changesin shift system operation. A sudden
¯ Movecontrol handle to the fast idle position to increase in shift effort at the remotecontrol handle, or
warmup engine. Do not exceed 1000 RPM. other abnormaloperation, indicates a possibleproblemin
the shift system.If this occurs,the followingprecautions
STARTING WARM ENGINE mustbe taken:
1. Movecontrol handle to the NEUTRAL

detent position. With enginerunningandboat securely tied to the
dock, shift drive into FORWARDand REVERSE to
2. Turn key switch to START position and hold until engine ensurethere is gear engagement.
starts, but do not hold in start position for morethan ten
seconds.If engine doesnot start, let go momentarily,then Whendocking the boat, all docking maneuvers
try again. must be performed at slow speed. Pay special
attention to other boaters. Passengers
shouldbe
3. As soon as engine starts, release key to the ONor RUN informed of potential problemsand precautions
position. taken.
Never turn key to STARTposition whenengine is if yoususpectthere is a problem,see your Volvo Penta
running. dealer as soonas possible for proper diagnosis and re-
quired service or adjustment.Continuedoperation could
result in damageto the shift mechanism andloss of shift
andthrottle controlthat cou|dresult in personalinjury.
6 CV-982.~,eng
STOPPING ENGINE 3. Watchthe enginetemperature

indicator to be sure the~re
is properwater circulation,
1. Movecontrol handle to the NEUTRAL
position.
Failure to follow the break-in procedurewill void the
2. Turn ignition key to the OFFposition. engine warranty.
~] Do not stop engine at speeds above idle or "speed First TwoHours

up" enginewhile turning off ignition. Enginedamage
could
result. For the first five to ten minutes of operation, operate
engineat a fast idle (above1500RPM).During the remaining
ENGINE BREAK-IN first two hours of operation, accelerate to bring boat onto
plane quickly and bring throttle backto maintain a planing
~] Failure to follow the Engine Break-In procedure can attitude. During this period, vary the engine speedfre-
result in serious enginedamage. quently by accelerating to approximately three-fourths
throttle for two to three minutes, then back to minimum
All Vo/vo Pentaengineshavebeenrun for a short period planing speed.
of time as a final test at the factory. Youmust follow the
Engi=~eBreak-in procedure during the first 20 hours of After the engine has reached operating temperature,
operation to ensure maximumperformance and longest momentarily reduce engine speed, then increase engine
enginelife. speed,1:o assist the break-in of rings andbearings.Maintain
planing attitude to avoid excessiveengine load.
~] To ensure proper lubrication during the break-in peri-
od, do not removefactory break-in oil until after the 20-hour DO NOT RUN ENGINE AT ANY CONSTANTRPM FOR
breallc-in is completed. PROLONGED PERIODSOF TIME FOR THIS INITIAL TWO
HOURSOF BREAK-IN.
During the break-in period, be particularly observant
during the initial runningof the engine,as follows: Next Eight Hours
1. C~¢kmotoroil level frequently.Maintainoil level in the During the next eight hours, continue to operate at ap-
safe range, betweenthe "add" and "full" markson dipstick. proximatelythree-fourths throttle or less (minimumplaning
Somewhat higher oil consumptionis normal until piston speed). Occasionally reduce throttle to idle speed for
rings have seated. cooling period. During this eight hours of operation it is
permissibleto operateat full throttle for periodsof less than
~] If you have a problemgetting a goodoil level reading two minutes.
on dipstick, rotate dipstick 180° in tube.
DO NOT RUN ENGINE AT A CONSTANTRPMFOR PRO-
Whenadding motor oil, refer to Motor Oil, in Fuel and LONGEDPERIODSOF TIME DURINGTHE BREAK-INPERI-
Lubricationsection. OD.
2. Watchthe oil pressuregauge.If the indicator fluctuates Final TenHours

whenever the boat attitude (i.e. turning, climbing on plane,
etc.) is changed,it maybe the oil pickup screen is not Duringthe final ten hoursof break-in, it is permissible’to
coveredwith oil. Checkcrankcasedipstick. Addoil to the operateat full throttle for five to ten minutesat a time. After
crankcase if required. DONOTOVERFILL. If oil level is warming engine to operating temperature, momentarily
correct andconditionstill exists, seeyourdealerfor possible reduce then increase engine speed. Occasionally reduce
gaugeor oil pumpmalfunction. enginespeedto idle to provide cooling periods.
~] Oil pressure will rise as RPMincreases, and fail as DO NOT RUN ENGINEAT A CONSTANT RPMFOR PRO-
RPMdecreases, in addition, cold oil will generally show LONGED PERIODSOF TIME DURINGTHE BREAK-IN PERI-
than hot oil. Bothof OD.
higher oil pressurefor anyspecific RPM
these conditions reflect normalengine operation.
At the end of the break-in period (20 hours), removemotor
oil and replace the oil filter. Fill crankcasewith recom-
mendedmotor oil.
17
®
@@
DR5194 DR5195
OPERATION AFTER BREAK-IN POWERTRIM/TILT SWITCH OPERATION

After break-in, the engine can be operated at any RPM [~] l~ The trim/tilt switch allows you to raise and lower
from idle to full throttle. However,cruising at 3600RPM or the drive unit. Hold the trim/tilt switch in the ~ UPposition
less savesfuel, reducesnoise, and prolongsenginelife. to trim up to the maximum trim position. Continue holding
the trim/tilt switchin the ~ up position to raise the drive unit
Be sure to checkthe oil level frequently duringthe first 50 to the maximum tilt position. Hold the trim/tilt switch in the
hours of operation, since the oil consumptionwill be high DOWN position to lower and trim downthe drive unit.
until the piston rings are properly seated.
Alwaysallow the trim/tilt switchto return to its center
PUMPING BILGE position whenthe drive unit reaches the maximum raised or
loweredposition. This will preventyour trim/tilt motorfrom
Frequentlycheckbilge for leaking engine, powersteering, overheating.
or trim systemoil. Find the causeandcorrect it immediately.
Federal, State or local regulationsprohibit the pumping of The trim/tilt motor is protected from overheating by an
oil into am/navigablewaters. internal thermal overload switch. Shouldthe electric motor
stop while tilting, releasethe switch andallow the overload
POWER TRIM/TILT SWITCH AND GAUGE switch to cool and automatically reset itself. Whenthe
LOCATION overload switch has reset, tiJting maybe resumed. Make
sure the drive unit is not being restrained, causingthe motor
Thepowertrim/tilt switch is located on the remotecontrol to overheat.If the electric motorstill doesnot operate,check
handle or on the boat’s dashboard. The power trim/tilt the 10 ampfuse and the 50 ampcircuit breaker. Refer to
Circuit Breakersand Fuses, in Specifications andMainte-
gaugesshow the corresponding bowposition. nancesection.
[] Single Engines:
POWER TRIM OPERATION
(~ Powertrim/tilt switch - remotecontrol handle
@ Powertrim/tilt switch - dash mounted Thepowertrim is normallyused prior to accelerating onto
plane, after reaching the desired RPMor boat speed, and
@ Powertrim/tilt gauge
whenthere is a changein water or boating conditions.
[] Twin Engines: Locate passengersand equipmentin the boat so that the
weight is balancedfore and aft, and side to side. Trimming
(~ Powertrim/tilt switches - remotecontrol handle will not cancel an imbatancedload.
® Power trim/tilt switch - dash mounted
(~ Powertrim/tilt gauges
8 CSVm25/eng
®@ ®@
DR202 DR2027
[]~] F4--] To operate the trim, pushand hold the switch OPERATING IN "BOW-UP" POSITION
"’bow..up" (~ or ~; "bow-down" ~ until the desired bow
position is reached. The trim maybe operated at any boat ~-~ The(O) "bow-up"position is normallyusedfor cruising,
speed or at rest. Avoid operating the trim system when running with a choppywavecondition, or running at full
running in reverse. Observethe trim/tilt gaugewhich indi- speed,in the full ~g "bow-up"position, the boat maytend to
cates the bowposition achieved. The midpoint of the trim turn. You mayhave to compensatewith the steering wheel
gaugescale indicates the highest 9 "bow-up"position, and to keepthe boat in a straight aheadpath. in this position the
bottom of the trim gaugescale indicates the lowest ,~ boat’s bowwill tend to raise clear of the water. Excessive(~,
"bow-down" position. "bow-up"trim will causepropeller ventilation resulting in
propeller slippage. EngineRPM will also increase, however,
DuoProp® Power Trim Operation boat speedwill not increase and mayeven drop.
The DuoPropdrive unit maybe operated within the trim Safety Warning:Use caution whenoperating in rough
range limits of -2° to +5°. When
operating outside of trim water or crossing another boat’s wake. Excessive~ "bow-
range the engine speed must be reduced to 1000 RPM. up" trim mayresult in the boat’s bow rising rapidly,
possibly ejecting the occupants.
/~ Safety Warning:Operatingthe DuoPropsterndrive at
enginesspeedshigher then 1000 RPMoutside of the trim OPERATING IN "BOW-DOWN" POSITION
limits (-2 = to +5=) could causeundesirableboat handling
cherac,~eristicsresulting in the loss of control. Thedrive [~ The ~_~ "bow-down" position is normally used for
unit c~malso be damaged if the enginespeedis above1000 acceleration onto plane, operating at slow planing speeds,
RPMwhenoperating in the trim/tilt angle between+5° to and running against a choppywavecondition. In the full
+30°. Neveroperatethe enginewith the drive unit tilted "bow-down"position the boat maytend to turn. Youmay
more’then +30° or the drive will be damaged. have to compensatewith the steering wheel to keep the
boat in a straight aheadpath. In this position the boat’s bow
DETERMINING THE PROPER TRIM will tend to go deeperinto the water. If the boat is operated
at high speedand/or against high waves, the bow of the
The effect of the maximum9 "bow-up" and <@"bow- boat will plow into the water. The boat maytend to bow
down"positions will be similar for most boats. The bow steer or spin about rapidly and possibly eject occupants.
position that is best for your operating conditions could be
at any trim setting betweenthe maximum ~ "bow-up" and Z~ Safety Warning:The boat trim should be adjusted to
"bow-down"positions. provide balanced steering as soon as possible each time
you get underway. Someboat/motor/propeller combina-
The boat will be properly trimmed whenthe trim angle tions mayencounter boat instability and/or high steering
provides the best boat performance for your particular torque whenoperated at or near the limits of the "bow-up"
operaling conditions. On models without power steering, or "bow-down" positions. Boat stability and steering
the trim position that provides a balancedsteering load is torque can also vary due to changingwater conditions, if
desirable. you experienceboat instability and/or high steering torque,
return to port at reducedspeedandsee your Volvo Penta
To fi~miliarize yourself with powertrim, maketest runs at dealer to correct these conditions.
slowerspeedsand at various trim positions to see the effect
of trimming. Note the time it takes for the boat to plane.
Watch the tachometer and speedometerreadings and the
ride action of the boat. Readthe following paragraphsunder
Operating in "Bow-Up" Position and Operating in "Bow-
Down"Position.
37252
I~~ __ STA___
RTINGANDOPERATION_
POWER
TILT OPERATION SALT WATEROPERATION
[~ ~ The tilting feature of the drive unit is controlled by YourVolvoPentasterndrive is built for operationin either
the trim/tilt switch. When the trim/tilt switchis held in the fresh or salt water. Fresh water internal flushing is recom-
"bow-up"position the drive unit tilts up until the switch is mendedafter use in polluted or salt water. Contact your
releasedor the drive unit reachesthe maximum tilt position. Volvo Penta dealer for an EngineFlushing Kit that allows
Thetrim/tilt gaugewill indicate the "tilt" position whenever flushing of the engine, whenin or out of the water.
the drive unit is in the tilt range.

If boat is moored
for long periods, tilt drive unit out of the
DONOTexceed 1000 RPMwhenoperating the drive water (except during freezing temperatures). After remov-
unit in the tilted position, propeller damage can occur. ing the boat from the water, lower drive unit to the run
Neverrun the enginewhenthe drive unit is tilted morethen (down) position until the cooling systemhas drained thor-
30° or the drive will be damaged. oughJy.
Tilting is normallyusedfor raising the drive unit to obtain The entire Volvo Penta sterndrive’s exterior should be
clearancewhenbeaching, launchingfrom a trailer, or moor- rinsed with fresh water, dried, and sprayed with anti-
ing. When tilting the drive unit, the boat shouldbe at rest or corrosion spray, fonlowing the directions on the container.
at idle speedonly. Refer to ShallowWaterOperationin this
section. TRAILERINGYOURBOAT
[~ Do not operate the drive unit out of water even Before movingyour boat, check the ground clearance of
momentarily; the water pumpmay be damagedor engine the drive unit. Whentrailering, the drive unit maybe in the
mayoverheat. up or downposition. Theremust be at least 15 in. (38,1 cm)
clearancebetweenthe lower gear unit and the ground.If the
Z~ Safety Warning: clearanceis less than 15 in. (38,1 cm), raise the drive unit.
a To avoid possiblecontact with the propeller, never Usecaution whenbacking out of driveways or cross-
usethe driveunit as a ladderor as a lift to boardthe ing railroad tracks, so that the lower gear unit doesnot hit
boat. Neverboardat the rear of the boat whenthe the ground.
engineis running,evenif the engineis operatingin
neutral. Personalinjury couldresult fromcontact It is extremely important that the boat fit the trailer
with rotating engineparts andpropeller. properly. Loss of performanceand speed, in manycases, is
due to improper trailer support and excessive tie-down
¯ Anymalfunctionof the trim/tilt systemcouldresult pressure which has causedthe boat bottom to deform. The
in a loss of impactprotection.Malfunction can also boat should rest firmly on the trailer with maximum tie-
result in loss of reversethrust capability, if malfunc- downpressure applied at the bow and transom only.
tion occurs, see your VolvoPentadealer.
0 CV-9825/eng
m
SHALLOW WATER OPERATION If the power steering system becomesinoperative, .~n

increasein steering effort will be felt. Shouldthis condition
Ti~lting the drive unit to reducethe draft for shallowwater occur, inspect for possible causeand correct condition if
running maybe done providing you DONOTEXCEED 1000 possible. If the powersteering systemcannotbe corrected
RPM.Exceeding 1000 RPMis not necessary. It will only on board, proceed at a reduced speed. The boat will be
increase the boat wakeand will not increase boat speed steerable, but with increasedeffort. Seeyour Volvo Penta
appreciably. dealer as soon as possible to correct your powersteering
system.
N~,’} Exceeding 1000 RPMcould damagedrive train com-
ponents. This type of damageis not covered by warranty. At slow speeds(no wake), your boat maytend to wander.
NEVERATTEMPTTO PLANETHE BOAT OR EXCEED1000 This is normal and maybe overcomeby anticipating bow
RPMWITHTHEDRIVEUNIT IN A PARTIALLYTILTEDPOSI- direction and correcting with steering wheel. A slightly
TION. ALWAYSRETURNTO THE TRIM RANGEAS SOONAS higher throttEe and trim setting mayalso lessen wander
POSSIBLETO AVOID DAMAGE TO DRIVE TRAIN. tendency.Changingweight distribution, aft to forward, can
also affect slow speedsteering.
Whenoperating in shallow water, be sure the water
intakes located in the lower gear unit are submerged at all TWIN UNIT STEERING
times. Proceedat slow speedand lower drive unit immedi-
ately whendeeperwater is reached. Twin engine boats mayhave only one engine with a fully
operational power steering system. That power steering
N[’~] Never run the engine whenthe drive unit is tilted systemis on the starboard engine; therefore, whenopera-
morethen 30° or the drive will be damaged. ting on a single engine use the starboard engine.
HIGH ALTITUDE OPERATION Usingthe port enginethat doesnot havethe function-

al powersteering systemwill cause an increasedeffort in
A performanceloss at altitudes above5000 ft. can be steering control, due to absenceof powerassist.
expected. If you are boating above5000ft. altitude for a
shor~Ltime, a lower pitch propeller will restore someof the Sometwin engine boats may have both engine power
lost performance.Longterm use abovealtitudes of 5000ft. steering systemscoupledtogether with a priority valve. This
mayrequire a changein gear ratio. allows the use of either engine to provide powerassist
steering.
OPERATING PROCEDUREFOR FREEZING
TEMPERATURES TWIN LINE MANEUVERING
Whenfreezing temperaturesare forecast and the boat will Whenleaving or approachingthe dock, or for any close
be operatedandwill be left in the water, the drive unit must maneuveringat slow speed, place the starboard engine in
remainin the tilted down(submerged) position at all times NEUTRAL, on standby, and use the port engine with the
to prevent water in the drive unit from freezing. Upon control nearest the operator. Theuse of one control is very
completion of engine operation, drain the engine as de- effective and moreconvenient.
scrib,~d in Off-Season StoragePreparationsin Specifica-
tions andMaintenance section. In the event that the port enginebeing usedfor maneuver-
ing stops, you can immediately go to the starboard engine
STEERING SYSTEM which has been on standby.
,~ Safety Warning:If maneuvering with the engine that
The steering system for your Volvo Penta sterndrive is
operated by a steering cable connectedto the helm. Re- has the power steering pumpand it stops, the power
strictiing movementof the steering cable will limit or stop steeringassist is lost. Failure to follow the abovemaneu-
the s~Ieeringsystem’shydraulicassist. vering procedurecouldresult in a collision andpersonal
injury.
Donot interfere with or restrict steering cable move-
mentthroughthe last 90° of bendat the engine. Donot use Both enginesmustbe running during close maneu-
cable retainers, clampsor tie straps. Using one or all of vering or at slow speeds.Watermaybe forced back through
these could restrict the cable movement near the engine. Do the underwater exhaust outlet and cause serious engine
not tie wiring harnessesor other control cables to the damageif only one engine is running. Do not attempt to
steering cable. Makesure deck combing and bulkheads plane boat while operating on a single engine. The propel-
allow for steering cable movement. lers are selected for the boat with the consideration that
both engines operate together. Operating with a single
engine could cause engine damage.
lOO%
90%
80%
® 70%
60%
5o%
40%.
30%
I}R3A06
PROPELLER SELECTION If using D-series aluminumpropeller sets, you must

also use an In-Trim Limiter Kit, P/N 3857598-1,available

E~ Your Volvo Penta dealer has chosen a propeller de- from your Volvo Penta dealer
signed to deliver top performanceand economyunder most
conditions. To obtain the maximum percentageof available BOTTOM PAINTING
horsepower~), the engineRPM at full throttle should be in
the specified full throttle operatingrange ~). Refer to If your boat is in water wheremarinegrowthis a problem,
Specificationsin Specifications andMaintenance section the use of an anti-fouling paint will reducethe growthrate.
for RPMrange. Be awareof laws that maygovern your paint choice and its
use.
Propellers that allow wide open throttle operation
(W.O.T.) at the upper end of the RPMrange provide faster ¯ A pure Teflon®-basedagent is recommended
for both the
planningtime for water skiing or similar activities. Propel- boat and drive unit.
lers that place W.O.T. RPMin the middle of the range
provide improvedcruising fuel economy. e Copperbase anti-fouling paint maybe used, but will
require morefrequent inspection and replacementof sacrifi-
If the engine’s full throttle RPMwith a normal load is cial anodes. DONOTPAINTany part of the drive unit or
belowthe specified range or on the low side of the range, transomshield with copper base anti-fouling paint.
use propeller(s) with less pitch to increase the RPM.Should
the engine’s full throttle RPM exceedthe specified range, [~ Painting the drive unit and transom shield with cop-
use propeller(s) of higher pitch to decreasethe RPM. per base paint will accelerate galvanic corrosion. A 1 in.
border must be left around the transomshield whenpaint-
[~ ~ Engine damagecan result from incorrect propel- ing the boat bottom.
ler selection which:
¯ Vinyl-butyl base anti-fouling paint is a recommended
© ¯ Prevents engine RPMfrom attaining the specified alternative.
"full throttle operating range." Engineis laboring.
Install lowerpitch propeller(s). ¯ DONOTUSEany graphite base anti-fouling paint.
i Allows engineRPMabovethe specified "full throttle Neverpaint sacrificial anodes,or their effectiveness
operating range." Engine is overspeeding.Install will be lost.
higher pitch propeller(s).
See your dealer for an EPAapproved anti-fouling paint
D-series aluminum propeller sets are not recom- that is suitable for your area.
mendedfor use on DuoProp®equipped boat and engine
combinations that are capable of speeds in excess of 40
MPH.E-series stainless steel propeller sets should be used
in these applications.
2 CV-9825/er~
Active Corrosion Protection System............. 3g Engine Submersion ......................... 28

Backfire Flame Arrestor ...................... 26 Exhaust System ............................ 27
Ba’~tery ................................... 23 Fuel Filters ................................ 26
Belt Adjustments ........................... 28 Fuel Pump(Electric) ......................... 26
Boat Bottom ............................... 30 Fuel System ............................... 26
Ca~rburetor Adjustment ....................... 27 High Tension Lead Routing ................... 26
Checking CrankcaseOil Level ................. 31 Ignition System ............................ 25
Circuit Breakers and Fuses .................... 25 Maintenance Log ........................... 46
Cooling System ............................ 29 Maintenance Schedule ....................... 42
De;~ler Service - 20 Hour Check................ 29 Off-Season Storage Preparation ................ 40
DuoPropDrive Unit Section ................... 35 Oil Filter .................................. 31
r)rive Unit Lubrication ...................... 35 Replacement Parts .......................... 39
l)uoProp Propellers ........................ 38 Sacrificial AnodeReplacement................. 38
External Lubrication Points .................. 36 Specifications .............................. 41
F~ropeller Care ............................ 36 SX- Single Propeller Drive Unit Section ......... 32
Propeller Replacement ..................... 37 Drive Unit Lubrication ...................... 32
]win Installations ......................... 36 External Lubrication Points .................. 33
Draining and Filling the EngineCrankcase........ 31 Propeller Care ............................ 33
Draining Cooling System ..................... 30 Propeller Replacement ..................... 34
Electrical System ........................... 23 Trouble Check Chart ......................... 44
Engine Alignment .......................... 25 Volvo Penta DuraPlus " Brand Products .......... 45
ELECTRICAL SYSTEM Z~ Safety Warning:
Theengine’s electrical systemfeatures cranking, charg- ¯ Do not exposebattery to electrical sparksor an

ing, ignition and trim/tilt circuits. Poweris providedby a openflame. Donot usejumpercablesanda booster
battery and all necessarywiring. battery to start engine.Removebattery front boat
to recharge.Donot rechargebattery in boat. Fumes
[~]1 If electrical connectionsare reversed, or connections vented during battery charging can lead to an
removedwhenkey switch is on or engine is running, the explosion.
electrical system mayimmediately be damaged.
¯ Batteryelectrolyteis a corrosiveacid andshouldbe
Alternator handledwith care. If electrolyte is spilled or
splashed on any part of the body, immediately
Thealternator is belt driven by the engineand will charge flush the exposedarea with liberal amountsof
the battery at all engine speeds. Idle speed output is waterandseekmedicalattention as soonas possi-
approximately 20 amperesand rapidly increases to the ble.
maximum output at 2000 RPM.The transistorized voltage
regulator controls alternator output to protect the battery It is important that the battery connectionsare cor-
andother accessoriesin the electrical circuit. Thevoltage rect. The negative battery cable must be attached to the
regulator is an integral part of the alternator. negativeterminal (-) on the battery andthe engine’spositive
cable mustbe attached to the positive terminal (+) on the
BATTERY battery.
4.3 GL, GS: Use a 12 volt battery with a minimum360 Inspectyour battery at regular intervals for specific gravi-
Cold Cranking Amp(CCA)rating at ° F(- 18° C)and115 ty (state of charge), individual cell water level, cleanliness
minu’tes reservecapacity rating at 80° F (27° C) (70 ampere- and tigllt, greasedconnections. If the battery has become
hour reference). discharged for no apparent reason, check all electriCal
systemcomponents for malfunction, or a switch left in the
5.0 GL: Use a 12 volt battery with a minimum650 Cold ON position, before to installing a rechargedbattery.
CrankingAmp(CCA)rating at ° F(- 18° C)and165 minutes
reservecapacity rating at 80° F (27° C).
5.7 GS: Usea 12 vott battery with a minimum650 Cold

CrankingAmp(CCA)rating at ° F(- 18° C)and165 minutes
resettle capacityrating at 80° F (27° C).
3524? 35246
I I1¸111 I
II I
/~ Safety Warning:Failure to follow the safety precautions [~ Z~ Safety Warning: The battery terminal connections
belowmayresult in electrical sparks igniting fuel vapors must always be insulated. If the battery mountingsystem
causingfire or explosion. does not cover the connections, insteU protective covers.
This will help prevent shorting o¢ arcing at the battery
Operateboat’s bilge blowerfor at least 5 minutes. terminals.
Openengine cover or hatch and checkthe boat’s

bilge area for gasolinefun-~s. If anyfumescanbe Z~Safety Warning:Battery electrolyte is an acidic solution
detectedby smell, do not operatethe boat until the and shouldbe handledwith care. If electrolyte contacts any
sourcecan be found, the spil| cleanedup, andthe part of the body, immediatelyflush the exposedarea with
causecorrected. water and seek medical attention as soon as possible.
DONOTconnect cables to battery until all other Multiple Batteries and Selector Switch
electrical connections have been made.Makesure
the ignition switch is in the OFFposition before if your boat is equippedwith multiple batteries and a
removing or installing electrical equipment,check- selector switch, the engine should be operated with the
ing any electrical connections,or insta|ling battery selector switch set to the ALLposition. This will provide
cables. chargingsystemoutput to all batteries.
See your Volvo Penta dealer for recommendationson A battery isolator is recommended
if batteries will be
installing multiple batteries. switchedfor individual operation.
Whenreplacing your battery, read and understand Battery Cables

the information supplied with it BEFORE
you begin installa-
tion. The following are the MiNiMUMspecifications for
strandedcoppercables from the motorto the battery for all
Batteries must be heavy-dutyand constructed for marine models. Themaximum length is 20 feet regardless of cable
use. Theycan be either vented/refiliabie, maintenance-free, diameter.
or deep-cyclewith a CCAor MCA rating. Refer to Specifica-
tions in this sectionfor battery size. [~ Do not use aluminumcore battery cables. Failure to
use battery cables of recommended gauge and material
~’~ Use bolts and nuts to secure battery cables to the could result in poor starting and electrical component
battery terminals. DONOTuse wing nuts to secure battery damage.
cables, evenif they were supplied with the battery.
¯ 0 to 10 ft. (3,05 m) require a 1/0 AWG (80 MWG)
[~ Loose battery connections can cause damageto the cable
engine’selectrical system.
¯ 10 to 15 ft. (3,05 to 4,6 m) require a 2/0 AWG(100
Service electrical components only while the motor is MWG)cable
NOTrunning. Be careful whenidentifying positive and
negative battery cables and terminals, if you touch the ¯ 15 to 20 ft. (4,6 to 6,1 m) require a 3/0 AWG (120
wrong terminal with a battery cable, even briefly, the MWG)cable
motor’s charging system could be damaged.
4 Cv-9825/eng
@
DR6450 46OO1 47564
CIRCUIT BREAKERS AND FUSES IGNITION SYSTEM
Volvo Penta sterndrive modelsare protected from over- Z~ Safety Warning: To prevent fire and explosion, Volvo
load by circuit breakersand fuses, if a circuit breaker is Penta ignition componentsmeet U.S.CoG.requirements for
tripped, it maybe reset. A blown fuse must be replaced, if external ignition proof parts. Donot substitute automotive
either continuesto fail, see your VolvoPentadealer. or other non-approvedparts.
[~ [’4~ The power trim/tilt motor is protected from over- Spark Plugs
load by a 50 ampcircuit breaker~). A second50 ampcircuit
breaker ® is usedto protect the main wiring harness. These To removespark plugs, detach spark plug lead from spark
circuit breakers are located on the starboard side of the plug by twisting rubber boot slightly and pulling off. Re-
engine. The electric fuel pumpcircuit is protected from movethe spark plug for inspection. Clean and check gap
overload by a 6 ampcircuit breaker © located on the fuel with feeler gauge; replace spark plugs each season.
pumpbracket.
The power trim/tilt switch is protected by a 10 amp
in-line fuse @located in the trim/tilt pumpwiring harness. ¯ Alwaysclean area around spark plug before remov-
ing spark plug completely.
Theignition switch and instruments are protected by a 20
ampfuse located in the main wiring harnessunder the dash e Before installing newspark plugs, alwayscheckfor
(at the ignition switch). proper type and gap. Incorrect type of spark plugs
can causeoperational problemsand possible inter-
Theinstallation of any additional electrical accessories hal engine damage.
requires the use of individual protected circuits. Power
takeoff should be madeat the battery. Seeyour Volvo Penta Before installing a spark plug, the spark plug seat in the
dealer for assistance. cylinder headshould be wipedclean. Tighten plugs only to
the recommended torque. Makesure the spark plug termi-
Avoid sparks that will damagecomponents. Do not nals are fully seatedon the spark plugs.
attempt to connector disconnectany part of the electrical
systemwhile the key switch is on or the engineis running. For recommended spark plugs, plug gap and installation
torque, refer to Specifications in this section and to the
ENGIINE ALIGNMENT tune-up decal located on the top of the circuit breaker
housing.
Enginealignmentrequires special tools and that the drive
unit be removed.This should be donewhenthe drive unit is Z~ Safety Warning:
removedfor lubrication during off-season storage prepara-
tions. Becauseof the special tools required, enginealign- ¯ Avoid abusive handling whichcould crack the spark
ment must be performed by a Volvo Penta dealer. plug’s ceramic body. Damagedspark plugs can
emit external sparks whichcould ignite any fuel
[~ Failure to check engine alignment could result in vapors in the engine compartment.
prematurefailure of engine coupler, universal joints, and
gimbal bearing.
A
l
@ ®__ --® ®
--® ®
DR2448 DR2453 46002
SPECIFICATIONSANDMAINTENANCE
¯ Donot operate engine if spark plug boots or high BACKFIREFLAMEARRESTOR

tension leads are tom or cracked. This condition
can allow external sparks which could ignite any [~ Remove the backfire flame arrestor ~) each year. Clean
fuel vapors in the engine compartmentand result in solvent, air dry, and inspect it for damage.Replaceif
in fire or explosioncausingpersonalinjury. damaged.Reinstall flame arrestor makingsure unit is se-
curely fastened.
Distributor Capand Rotor
A~ Safety warning: To prevent fire and explosion in the

Remove,inspect and clean distributor cap and rotor. engine compartment, the backfire flame arrestor must
Replace these componentsif worn or damagedwith genu- always be in place, properly secured, and undamaged.
ine Volvo Penta parts. No other distributor parts require
service or replacement. ELECTRICFUEL PUMP
HIGH TENSIONLEADROUTING Z~ Safety Warning: Frequently check pumpfor signs of
fuel leakage. Shouldthis occur, have it serviced immedi-
/~ Safety Warning: Inspect spark plug leads and boots for ately by your Volvo Pentadeeler.
cracks that would emit external sparks and possibly ignite
fuel vapors in the engine compartment. Do not operate All models are equipped with an electric fuel pump
engine with damagedleads. mountedin front on the starboard side of the engine. The
fuel pumpelectrical circuit is protected by a 6 ampcircuit
I-~ 4.3 GL, GSModels:Firing order 1-6-5-4-3-.2 breaker ®. The electric fuel pumpis activated only when
engineis running.
~-] 5.0 GLModels:Firing order 1-8-4-3-6-5-7-2
If the engine has stopped, or it will not start and you
I~ 5.7 GSModels: Firing order 1-8-4-3-6-5-7-2 suspect the fuel pumpis not activated, check the circuit
breaker. Refer to Circuit Breakersand Fusesin this section.
Whenspark plug leads are removed, be sure they are
replaced in the correct order as shown. If fuel or oil is visible in the orangeoverflow hose, have
your Volvo Penta dealer replace the fuel pumpimmediately.
FUEL SYSTEM
FUELFILTERS
Z~ Safety Warning: To prevent fire and explosion, service
proceduresare always performed with the engine stopped. ~] All modelshavea fuer filter © in the fuel line before the
After completing service procedures, start engine and fuel pump.
check entire fuel system for possible leaks. Failure to
inspect your work could allow fuel leakage to go unde- Z~ Safety Warning: Accumulation of water and other fuel
tected. This could becomea fire or explosion hazard. contaminants may form corrosive compoundswhich can
damage the fuel filter, resulting in fuel leakage. For this
Z~ Safety Warning: To prevent fire and explosion, Volvo reason, annualreplacementof the fuel filter is required to
Pentafuel system componentsmeet U.S.C.G. requirements avoid risk of explosionor fire.
for fuel and fuel vapor containment. Do not substitute
automotive or other non-approvedparts.
6 CV-9825/eng
®
46O01 DR3844
EngineFuel Filter CARBURETOR ADJUSTMENT

To clean or replacefuel pumpfilter: /~k Safety Warning: Engine cover is a machinery guard.
Removalexposes you to moving parts. Keep hands, hair,
1. Unscrewfuel filter; removeand discard. clothing awayfrom belts, pulleys and movingparts.
Z~ Safety Warning: Old filter contains flammablefuel. Changes in fuel, altitude and climate maymakeit neces-
Dis;poseof safely. saw to adjust the idle speed and idle mixture to obtain
smoothengine operation. Before attempting to adjust car-
2. Lightly lubricate the gasketon newfuel filter. buretor, ensurethat the backfire flame arrestor is free of
debris, dirt and grease. SeeBackfire FlameArrestor in this
3. Screwon fuel filter andhandtighten, following instruc- section.
tions onfilter.
Carburetor idle speedand mixture adjustmentshould
4. Cleanup anyspilled fuel. not be attempteduntil engine is warmand it is knownthat
ignition systemcomponents (including spark plugs) are
Z~ Safety Warning:5. Runbilge blower for at least five specifications. Anyattempt to alter the carburetor to corn-
minutes to vent engine compartment,then start engine pensate for faulty conditions elsewherewill result in re-
and checkfor leakage.Smellfor fuel in the bilges, if you duced fuel economyand overall performance. See your
car= smell fuel, explosionandfire are an extremedanger. Volvo Pentadealer for adjustment.
Clean up the bilges until fuel cannot be detected by
smell. EXHAUST SYSTEM
CarburetorFuel Filter Periodically inspect engine exhaust system. Checkfor
deteriorated or burned hoses, loose clamps, and evidem~
¯ o cleancarburetorfuel filter screen: of water leaks.
1. Disconnectfuel line at carburetor. /~ Safety Warning: Replace damaged/defective compo-
nents, andsecurely tighten all clamps,Anyexhaustleak
2. Remove
fuel inlet nut ~, gasket(~) and screen(~. must be repaired before boat is operated. Exhaust leaks
release fumes that can create hazardous conditions for
3. (;lean screen with solvent and blow dry. operator and passengers.
4. Install screen, gasket, and inlet nut. Tighten nut se-
curely.
5. Connectfuel line and tighten securely.

6. Cleanup anyspilled fuel.
Z~ Safety Warning: 7. Start engine and check for leak-
age.
c.e.,,°o. 27
DRC43344 43345
BELT ADJUSTMENTS PowerSteering PumpBelt
/~ Safety Warning:To prevent possible injury causedby Improperpowersteering belt adjustmentwill causea
someoneinadvertently starting the engine, removethe loss of powersteering assist, resulting in hard steering.
ignition keysfromeachstarting location(especiallyif the
engine room/engine compartmentcannot be seen from ~’] With engine off, check powersteering belt deflection
various remotestarting positions suchas a flybridge or midway® betweenthe circulating pumppulley @and the
endosedcabin)° power steering pumppulley ®.

Thebelts usedfor the alternator, water supply pump, To increase belt tension: Loosen pumpmounting
and power steering pumpare heavy duty. Do NOTreplace screws,insert a 1/z in. breakerbar into the squarehole ~) in
with automotivebelts. the pumpmounting bracket, and pivot pumpaway from
engine as shown. While maintaining pressure on pump,
Belt Tension retighten all mountingscrews. Recheckbelt tension. Never
pry against the pumpreservoir or pull filler ne¢lc
~’~ Belt tension is determined by belt deflection. With
engine stopped, the belt should be tight enoughso that it Water PumpBelt
will deflect 1/4 in. (6 mm)whenpressedwith the finger or
_ 10 lbs. (336,6 ± 44,5 N) using belt te nsion gauge at [-~ To increase belt tension: With engine off, checkwater
points @,®, and© shown,tfthe belt is too tight, excessive pumpbelt deflection midway@between the water pump
belt and bearingwearcan occur. If it is too loose, slippage pulley @and the crankshaft pulley ®.
can occur, resulting in belt wear, poor circuDating pump,
alternator, and power steering operation. Belt tension Loosen mounting bracket to water pumpscrews, and
should be checkedafter 10 hours of service and every 50 pivot water pumpawayfrom engine to increase belt ten-
hoursthereafter. sion. While maintaining pressure on water pump,retighten
top and bottom screws. Recheckbelt tension.
AlternatorBelt
ENGINE SUBMERSION
With engine off, checkalternator belt deflection mid-
way ~) between the circulating pumppulley O and the Removeengine from water as quickly as possible and
alternator pulley @. contact your local Vo/voPentadealer for service.
To increase belt tension: Loosen alternator mounting It is imperativethat your dealer removeall water from the
screwsand nuts, and pivot alternator awayfrom engine to engine and immediatelyreiubricate all internal parts. All
increase belt tension. While maintaining pressureon alter- electrical devicesmustalso be dried and inspectedfor water
nator, retighten top screw and bottom screw and nut. damage. Delay in completing these actions may allow
Recheckbelt tension. extensive engine damage.
Frequently check engine compartmentfor gasoline fumes

and excessive water accumulation; water depth in bilge
should be kept well below flywheel housing.
2 8 cswczs/an9
3725OA
SPECIFICATIONS AND MAINTENANCE IIIIII

IIII II I II III
DEALER SERVICE - 20-HOUR CHECK 14. Makesure engine can achieve maximum
rated RPM.
Seeenginespecifications.
To ensure your continued boating enjoyment, we recom-
mendthat you return your Volvo Penta sterndrive to your 15. Checkoil level in drive unit and addas necessarywith
VolvoPants dealer for a 20-hourcheck. Volvo Penta DuraP/us" GL 5 Synthetic Gear Lube (if
possible without removingthe boat from the water).
Dealer 20-Hour Check:
This is an opportune time to discuss with your Volvo
1, Change
engineoil andoil filter, Penta dealer any questions about your Volvo Penta
sterndrive which mayhave arisen during the first 20 hours
2. RepJace
the fuel/filter waterseparator. of operation and establish a routine preventive maintenance
schedule,
3. Checkpowertrim/tilt reservoir for properfluid level.
For the U.S., Canada,and Mexico, the 20-HourCheckis
/~ Safety Warning: 4. Checkflame arrestor for proper paid for by the boat owner and performed by your Volvo
mounting. Pentadealer at local dealer rates, in other markets, the
warranty inspection is paid for according to the warranty
Z~ Safety Warning:5. Start engineandcheckcomplete policy for importers.
fuel systemfor leaks.
COOUNG SYSTEM
~ Safety Warning:6, Lubricatesteering cable ramwith
t~)/vo Pentadensewaterresistant greaseor equivalent. [~ ~ Volvo Penta engines have a thermostatically con-
Checkpowersteering pumpreservoir for proper fluid trolled recirculating type cooling system. Cool water is
level. drawnin throughthe water inlets ® located on both sides of
the lower gearcaseby a water pumpmountedon front of the
/~ Safety Warning:7. Checkshift systemfor proper engine. Wateris pumped to the engineand circulated by the
adjustmentandoperation. engine water pumpthrough the cooling system.
Z~ Safety Warning:8, Inspect exhaustsystem,tighten IT] [~ A thermostat determines the amountof water 1:o
all hosedamps andcheckfor leaks. be taken in, recirculsted and dischargedto control engine
operating temperatures. Water is discharged through an
9. Checktension on all drive belts, idle exhaustrelief ®, and with exhaustthroughthe propel-
ter hub @and anti-ventilation plate ®. A temperaturegauge
10. Checkall enginemountscrewsfor tightness. located on your boat instrument panel will indicate if the
engine overheats. Donot operate engine without thermo-
11. Checkand adjust carburetor for correct idle mixture stat. The enginemayoverheatif the thermostatis removed.
and idle RPM.
[~ Shouldengine overheat, gradually throttle backto
12. Checkenginetiming. idle positionfor aboutoneminutebeforestoppingengine.
Tilt drive up andclear off anywaterpickupobstructions.
If
13. Checkfor any deficiencies, malfunctions, signs of overheatingcontinues,return to port at low RPMto pro-
abuse,etc. Correction of any problemsat this time will vent excessiveoverheatingand enginedamage.Seeyour
prevent the worsening of a minor problem and help VolvoPentadealer.
ensurea trouble-free boating season.
29
45996 45992 45986
The following steps are very important in protecting Pivot Housing

your engine and drive from damagefrom freezing condi-
tions. If you are unsure of how to perform any of the [~ To drain cavity in pivot housing,tilt drive unit to the full
following steps, see your Volvo Pentadealer for a complete tilt (up) position and removethe water drain plug (~ from
end-of-season/winterization service. Freeze damage to the port side of the pivot housing.Tilt the drive unit to the full tilt
engine/drive packageis not covered by your Volvo Penta downposition. Allow unit to drain. After unit has completely
limited warranty. drained, replace pivot housingplug. Inspect drive unit water
intake screenfor obstructions.

DRAINING COOLING SYSTEM
Oin Coolers
Performthis procedurewith boat out of water, it will
prevent damage to cooling systemcomponents if tempera- Remove the lower water hose from the oil cooler, tf cooler
tures drop belowfreezing. Whendraining the engine, raise is mountedhorizontally, removeeither hose, loosen mount-
or lowerthe bowof the boat to position the enginein a level ing bolt, and tip openend of cooler downto drain.
attitude. This will providefor cornpietedrainageof the block
and manifold. If the bowof the boat is higher or lower than [~ Failure to completely drain the cooling system and
the stern, somewater maybe trapped in the block. pivot housing will result in serious damage to the engine,
exhaust manifolds, pivot housing, and drive unit when
Engine temperaturesgo below freezing. To assure complete drain-
age, probeall drain openingswith a piece of wire to remove
[~ Front any blockage.
O Disconnect and drain large hose at water pumphous- BOAT BOTTOM

ing.
Thecondition of the boat’s bottom can affect your boat’s
® 4.3 Litre ModelsOn|y: Remove
intake manifold drain performance.Marine growth, present in fresh water as well
plug and drain manifold. as salt water, will reduce boat speed. A boat bottom with
evidence of marine growth can cause a reduction in top
~] Starboard speedof 20 percent or more. Periodically clean the bottom
of your boat following the manufacturer’s recommenda-
® Removeone cylinder block drain and clear hole with a tions. Bottom painting mayalso be desirable; see Bottom
wire. Painting in Starting andOperationsection.
(~ Loosenclamp and removemanifold hose.
~] Port
® Remove
one cylinder block drain and clear hole with a
wire.
® Loosen clamp and remove manifold hose.
Water Supply Pump
~] Loosenand slide clamps back. Removehoses from the

rear of water pumpand drain. Crank the engine no more
than 2 seconds(DONOTSTART)to expel any water trapped
in water pump. Reattach water pumphoses.
0 CV-9825/eng
42865 34087 46OO5
CHFCKING CRANKCASE OIL LEVEL [~ Removeoil fill cap © and fill the crankcase to the
specified capacity with a reputable brand of motor oil
Removedipstick from oil withdrawaltube. Theoil level must labeled for Service CE/SGwhich meets General Motors
be betweenthe two marks on the dipstick. Add oil as Standard GM-6094-M.Oils conforming to this standard
necessaryto maintain the proper level. contain detergent and anti-wear additives.
~l Do not allow level to go below "Add" mark. Do not fill Volw~Penta DuraPlus" HeavyDuty engine oil is labeled
above"Full" mark. Overfilling results in high operating for Service CE/SG.It exceeds General Motors Standard
temperatures,foaming(air in oil), loss of power,and overall GM-6094-M.It can be purchased from your Volvo Pen, ta
reducedenginelife. dealer.
DRAINING AND FILLING THE ENGINE [~ Donot fill abovefull mark. Overfilling results in high
CRANKCASE operating temperatures,foaming(air in oil), loss of power,
and overall reducedenginelife.
Motoroil and the oil filter are importantfactors affecting
engine life. They affect ease of starting, fuel economy, Crankcase Capacities - Refer to Specifications in this sec-
tion.
combustionchamberdeposits and engine wear. Drain and
refill crankcaseoncea seasonor every 100 operating hours.
OiL FILTER
[~ Checkthe motoroil level every 4 or 5 hours of operation
and add oil as necessary=Whenoil is to be changed,run Replacethe oil filter wheneverthe motor oil is changed.
engineto warmoil for easier removal. Remove dipstick and This filter is a self-contained, screw-ontype. To remove,
withdraw oil from crankcase through the dipstick tube ® unscrewfilter canister counterclockwiseand discard. When
using the special fitting providedon the tube. This special attachinga newfilter, be surethe gasketis lightly lubricated
fitting is providedso oil doesnot haveto be drainedinto the with motor oil. Handtighten only, run engineand checkfor
bilge. Withdrawoil with a suction pump.Disposeof usedoil leaks. Donot run engineout of water. Disposeof usedfilter
in accordancewith any applicable environmental regula- in accordancewith any applicable environmental regula-
tions. tions.
Safety Warning:To preventfire andexplosion, always Refer to Specifications in this section for replacement
oil
makesure engine compartmentis free of gasoline fumes filter, and Featuressection for locations of oil withdrawal
before usinganyspark=producing tools suchas the electric tube, dipstick, andoil filler cap.
drill motor used with oil withdrawal pumpkit.
31
34O86 47117
SPECIRCATIONS AND MAINTENANCE
SX - SINGLE PROPELLERDRIVE UNIT SECTION
DRIVE UNiT LUBRICATION [~’>’[~] To fill the drive unit, removethe three screws
securing the rear cover to access the oil level plug ©.
The drive unit is filled at the factory with Volvo Penta Remove oil level plug.
TM GL 5 Synthetic Gear Lube.
DuraPlus
¯ Fill drive unit with Volvo Penta DuraPlusTM GL5
AddingLubricantto Drive Unit Synthetic GearLube.Fill throughthe oil drain plug

location ®. Fill slowly to purgeair. Thedrive unit is
[’~ Every weekcheck the oil level in the drive unit (if properly filled whenthe oil appearsat the oil level
possible without removingthe boat from the water). Fully plug hole. When filled to the properlevel, install oil
thread the dipstick ~) into the hole, then removeand check level dipstick and oil level plug first to prevent
the oil level. Checkto makesure that the oil level comesto excessiveoil loss, then the oil drain plug. Tightenoil
the top of the flattened portion of the dipstick. Theoil should level and drain plugs securely.
appearan ambercolor. If any moistureis presentin the oil,
the oil will appearmilky. Also no metalflakes shouldappear ¯ If unableto fill drive unit throughoil drain plug ®,
in the oil. the drive can be filled by trimming it up a few
degreesand filling through the oil level plug ©.
If moistureor metal flakes appearin the drive unit, Reinstall oil level plug, and place drive in the run
take the boat to your Volvo Penta dealer immediately. (down) position. Remove dipstick ® and check oil
level. Reinstall dipstick and tighten securely.
If oil level is low, addonly enoughlubricantto bring the oil
level within the full rangeof dipstick. ¯ Install rear cover and tighten screwssecurely.
Theoil level in the drive unit mustbe checked by fully ¯ Checkoil level with the dipstick, oil mustappearon
threading the dipstick into the hole. Improperoil level may the full rangeof dipstick. Addoil if required through
result in serious drive unit damage. the dipstick hole. Refer to Specifications in this
section for drive unit oil capacity.
DrainingandFilling DriveUnit
[~ rT]’~] If drive unit was filled through the oil level
r~ [-~ Whena completechangeof lubricant is required in plug ©, wait 15 minutesbefore checkingoil with dipstick.
the drive unit, proceedas follows: This will help ensureall air is purgedfrom the oil cavity.
Leavedipstick @loose during waiting period.
¯ Placedrive unit in the run (down)position.
¯ Remove the oil drain plug ® (starboard side of lower
gearunit) andthe oil level dipstick (~ (top of drive
unit).
¯ Allow the drive unit to drain completely.Disposeof
used oil in accordancewith any applicable environ-
mentalregulations.
2 CV-9825/eng
8383 341O9

mIII I II II I I I I I
SX ~ SINGLE PROPELLERDRIVE UNIT SECTION
EXTEIRNALLUBRICATION
POINTS [~ The drive unit must be removedto lubricate the shaft
splines @with molybdenum filled grease. Apply a light coat
Thegimbal bearing MUST be lubricated each year. Lubri- of motor oil to the shaft O-rings ®. Checkthe bellows for
cate this componentwhenpreparing your boat for off- damage and deterioration. Replaceif necessary.Also check
seasonstorage. This requires the removalof the drive unit; enginealignment. Refer to EngineAlignmentin this section.
theret’ore, this operation shouldbe performedby your Volvo
Pentadealer. PROPELLER
CARE
Failure to lubricate the gimbal bearingeachyear will A damagedor unbalancedpropeller will cause excessive
resull in damage to the pivot housingand drive unit. vibration and a loss of boat speed. Underthese conditions,
stop the engine and checkthe propeller for damage.If the
~] The gimbal bearing is lubricated by a grease fitting propeller appears damaged,have it checkedby your Io¢~1
located on the side of the gimbal housing. Lubrication must Volvo Penta dea(er. Always carry a spare propeller and
be donewith the drive unit removed.Lubricate bearing with replace the damaged propeller as soon as possible.
EPwl~eel bearing grease. Apply greaseuntil all old grease
has been removedfrom bearing and newgrease appears. If Never continuously run with a damagedpropeller.
there is evidenceof water, the bearingshouldbe replaced, if Runningwith a damaged propeller can result in drive unit
damaged. and engine damage.
®
\
SX - SINGLE PROPELLER DRIVE UNiT SECTION

PROPELLERREPLACEMENT ¯ Coat the full length of the propeller shaft ® with

Volvo Pentapropeller shaft grease.
A rubber hub in the propeller is the shock absorber that
minimizes damageto drive unit and engine. If rubber hub ¯ Placethrust bushing<~ on propeller shaft with inner
should begin to slip, it can be easily replaced at a Volvo taper towardgearcaseto matchthe taper on propel-
Pentadealer or propeller service station. ler shaft.
/~ Safety Warning:Thefollowing is an emergency on-the- ¯ Install propeller ® onto propeller shaft, aligning
water propeller replacementprocedure.Protect your hands splines, and push propeller onto thrust bushing
from sharp edges of the propeller blades. Wear gloves until splines are exposed.
whenremovingor replacing the propeller.
¯ Instalt the thrust washer (~ on propeller shaft
r~ To RemovePropeller splines.
¯ Safety Warning:Ignition switch mustbe OFF. ¯ Shift the remotecontrol into REVERSE
gear to lock
the propeller shaft.
¯ Makesure remote control is in NEUTRAL
position.
¯ Install and tighten the propeller nut ® until its
¯ Removecotter pin Q and keeper ~. seated against thrust washer.
¯ Shift the remotecontrol into FORWARD
gear to lock ¯ Loosennut, then turn back against thrust washer
the propeller shaft. until finger tight. T~htennut an additionalI/3 to 1/2
turn.
¯ Remove
propeller nut ® using a 11/~6 in. wrench.
¯ Index keeper ® on propeller nut until aligned with
¯ Removethrust washer(~, propeller ®, and thrust cotter pin hole.
bushing ®.
¯ Install cotter pin O and bend ends to secure (use
¯ Wipepropeller shaft ® clean. Inspect for monofila- newcotter pin if necessary).
mentline; removeif present.
¯ Shift the remote control into NEUTRAL.
Propeller
[~] To install Propeller should turn freely (control in NEUTRAL).
¯ Makesure remote control is in NEUTRAL

position. Beforenext outing, use a torque wrenchto tighten
propellerto 70-80ft. Ibs. (96-108N.m). Thrust washer,nut,
keeperand cotter pin must be installed as shown.Failure to
install all componentscould result in loss of the propeller
whenboat is operated.
4 CV-9825/eng
/
34086 37250
DUOPROP®DRIVE UNIT SECTION
DRWEUNIT LUBRICATION F2-1->’[~] To fill the drive unit, removethe three screws
securing the rear cover to accessthe oil level plug (c~.
Thedrive unit is filled at the factory with Volvo Penta Remove oil level plug.
DumPlus" GL 5 Synthetic Gear Lube.
Fill drive unit with Volvo Penta DuraPlus~- GL 5
AddlingLubricantto Drive Unit Synthetic GearLube. Fill throughthe oil drain plug
location ®. Fill slowly to purgeair. Thedrive unit is
!~] Every weekcheck the oil level in the drive unit (if properly filled whenthe oil appearsat the oil level
possible without removingthe boat from the water). Fully plughole. When filled to the properlevel, install oil
thread the dipstick ® into the hole, then removeand check level dipstick and oil level plug first to prevent
theoil level. excessiveoil loss, thenthe oil drain plug. Tightenoil
level and drain plugs securely.
if oil level is low, addonly enough lubricant to bring the oil
level1 within the full rangeof dipstick. If unableto fill the drive unit throughoil drain plug
(~, the drive can be filled by trimmingit up a few
~ The oil level in the drive unit must be checkedby fully degreesand filling through the oil level plug ©.
threading the dipstick into the hole. Improperoil level may Reinstall oil level plug, and place drive in the run
result in serious drive unit damage. (down) position. Remove dipstick ~) and check
level. Reinstall dipstick andtighten securely.
DrsiningandFilling DriveUnit
¯ Install propellers, refer to Propeller Replacement in
[~ I-~ Whena completechangeof lubricant is required in this section.
the drive unit, proceedas follows:
¯ Install rear cover and tighten screwssecurely.
¯ Place drive unit in the run (down)position.
e Checkoil level with the dipstick, oil mustappearon
¯ Removepropellers and mounting hardware. the full rangeof dipstick. Addoil if requiredthrough
the dipstick hole. Refer to Specifications in this
N[’~ RemovingDuoProppropellers require the use of section for drive unit lubricant capacity.
special tools. Refer to Propeller Replacement in this section.
[~ [~’>~} If drive unit wasfilled through the oil level
¯ Remove the oil drain plug ® (below propeller shaft) plug ©, wait 15 minutesbefore checkingoil with dipstick.
andthe oil level dipstick ® (top of drive unit). This will help ensureall air is purgedfrom the oil cavity.
Leavedipstick ~) loose during waiting period.
¯ Allow the drive unit to drain completely. Disposeof
used oil in accordancewith any applicable environ-
mental regulations.
cv_.;:,oo, 35
8383 34109 DR5176

II
~ DRIVE UNiT SECTION

DUOPROP
EXTERNALLUBRICATIONPOINTS TWIN INSTALLATIONS_

The gimbal bearing MUST be lubricated each year. Lubri- DuoPropdrive units have counter-rotating propellers.
cate this componentwhenpreparing your boat for off- Thereis no needto alter the direction of rotation of the drive
seasonstorage. This requires the removalof the drive unit; units in twin installations.
therefore, this operation should be performed by your

Volvo Penta dealer. [~ In DuoPropdrive unit twin installations the drive unit
must be adjusted so operation is free from ventilation. To
Failure to lubricate the gimbal bearingeach year will adjust, measurethe distance © betweenthe center line of
result in damage to the pivot housingand drive unit. the two transomshields. Adjust tie bar so the distance
betweenthe center of the anti-ventilation plate is equatto
The gimbal bearing is lubricated by a grease fitting distance ©.
located on the side of the gimbal housing. Lubrication must
be donewith the drive unit removed.Lubricate bearing with Hold the drive units whenmeasuring.
EPwheel bearing grease. Apply grease until a~l old grease
has been removedfrom bearing and newgrease appears. If PROPELLERCARE
there is evidenceof water, the bearing should be replaced.
A damagedor unbalancedpropeller will cause excessive
[~ The drive unit must be removedto lubricate the shaft vibration and a loss of boat speed, Underthese conditions,
splines (~ with molybdenum filled grease, and apply a light stop the engine and check the propellers for damage,if a
coat of motor oil to the shaft O-rings ®. Checkthe bellows propeller appears damaged,have it checkedby your local
for damageand deterioration. Replaceif necessary. Also Volvo Penta dealer. Always carry spare propellers and
check engine alignment. Refer to EngineAlignmentin this replace a damagedpropeller as soon as possible.
section.
[~ Never continuously run with a damagedpropeller.
Runningwith a damagedpropeller can result in drive unit
and engine damage.
6 CV-9825/eng
DR5387
DUOPROP®DRIVE UNIT SECTION

PROPELLERREPLACEMENT ~’] ToInstall Propellers
A rubber hub in the propeller is the shockabsorberwhich ¯ Coat the full length of both propeller shafts with
minimizesdamage to the drive unit and engine. If the rubber Volvo Pentapropeller shaft grease.
hubshouldbegin to slip, it canbe easily replacedby a Volvo
Penta,dealer or propeller service station. ¯ Place remote control in the FORWARD
position to
lock propeller shafts.
L~ Safety Warning: Whenreplacing propellers, protect
your I~ands from sharp edgesof the propeller blades. Wear ¯ Install front propeller @.
gloves whenremovingor replacing the propellers.
¯ Install front propellernut ® andtighten to 45ft. I5,s.
L~ S=lfety Warning: Donot attempt to hold propellers by (60 N-m).
hand whenremovingor installing the propellers, serious
injury couadresult. ¯ Place remote control in the REVERSE
position "to
The. following is an emergencyon-the-water propeller
replacementprocedureand requires the use of the special ¯ Install rear propeller ®.
tool kit (3855516-5).
¯ Install the rear propeller nut 0 andtighten to 50 ft.
[~ To> RemovePropellers Ibs. (70 N-m).
¯ L~ Safety Warning: Ignition switch must be OFF. Failure to install propellers as showncould result in
the loss of the rear propeller and damage to the drive unit
¯ Place remote control in the FORWARD
position to whenboat is operated.
¯ Remove
rear propeller nut Q.
¯ Remove
the rear propeller ~.
¯ Place remote control in the REVERSE
position to
¯ Remove
the front propeller nut ®.
,i Remove
front propeller @.
¯ Wipepropeller shafts clean. Inspect for monofila-

mentline; removeif present=
DR5382 DR5417
SPECiFiCATiONS AND MAINTENANCE
DUOPROP~ DRIVE UNiT SECTION

DUOPROPPROPELLERS A damagedpropeller must be changedwithout de-

Jay. Operatewith extremecaution if a propeller is dam-
The propellers for the DuoPropdrive units have applica- aged. Do not operate with only one propeller, this can
tion and diameter/pitch identificatior~ symbols,DOthrough causedamage to the propeller shafts.
D9for aluminumpropellers and F4 through F9 for stainless
steel propellers. The single numberrepresents the diamet- SACRiFiCiAL ANODE REPLACEMENT
er/pitch. The DuoProppropellers (forward and rear) must
operatein sets of the matcheddiameters/pitches.Propellers [~ F~ Sacrificial anodesare attached to the bottom of
in a set will have the sameidentification symbol with the gimbal housing ©, and at the front of the gearcase
different part numbers.Thesesets must be maintained, and above the anti-ventilation plate @. Anodesare slowly
for twin installations both drive units must always have erodedawayby galvanic action and require inspection.
propellers with the sameidentification symbols.
inspect gimbal housing and front gearcase anodes
r-~ ~ The identification symbol (~ and the front and rear every 14 days, or morefrequently if used in extremelysalty
identification ® are stampedon the end of the propeller water.If an anodeis %its original size (1/3 eroded),it should
hubs. Whenreplacementof a propeller is required, either a be replaced.If a staintess steel propeller is used, additional
forward or rear propeller can be purchasedto maintain the sacrificial anodesmaybe required to handle the added
matchedset. Always order replacement propellers by the corrosion potential.
part number.
Whenreplacement is required, see your Volvo Penta
Your Volvo Penta sterndrive should be equipped with dealer. The material composition of Volvo Penta anodes
propellers designed to give top performanceand maximum meetsU.S. Military Specification 18001-H. if other than
economyunder all operating conditions. To obtain peak Volvo Penta anodesare used, makesure they have equiva-
performance, the engine RPMAT FULLTHROTTLE must fall lent specifications or galvanic corrosion protection will be
in the specified operating rangeat normalload conditions at lost. If additional electronic or electrical equipmentis in-
favorable/besttrim settings. stalled; each should have an individual anodeor grounding
device and all grounding devices must be interconnected.
if full throttle RPMis below the recommended operating Follow equipment manufacturer’s recommendations.
range, propellers with less pitch shouldbe used. Shouldfull
throttle RPMexceed the recommended range, install pro- [~ r~ Whenthe boat is primarily used in a fresh water
pellers of higher pitch. Selecting the correct propellers to environment, Volvo Penta recommendsreplacing the zinc
allow the engineto run at full throttle in the recommendedanode ® with a magnesiumanode.
operating rangewill give the best enginelife, fuel economy,
and performance.Seeyour Volvo Penta dealer for help in
determiningthe correct propellers for your application.
8 CV-9825/eng
340e3A 37250A
SPECIFICATIONS
II1
AND MAINTENANCE
IIII iii j FI II
II~
ACIWE CORROSION PROTECTION SYSTEM __ SafetyWarning:Improperparts substitutioncan result

in fire or explosion.
Your boat maybe equippedwith an optional Volvo Penta
Active Corrosion Protection Systemthat greatly improves ¯ Whenreplacementparts are required, use Vo/vo
Pentaereplacement parts. VolvoPentareplacement
the life of the drive unit by protecting it from corrosion, if

you do not havethis system,it is available from your Volvo parts are designed to meet USCGrequirements
Penta dealer under part number3851984-9. This system andABYC standardsfor marineapplications. Fail-
operates with very little current drain from the boat’s ure to do so mayresult in productmalfunctionand
electrical system. possibleinjury to the operatorand/orpassengers.
The protection system’s control box has a small LED Substituting automotiveor generally supplied parts and
indicator light that blinks onceevery one to five secondsto hardwarewill often result in less than desired performance.
showthe systemis operatingproperly. Thelight will blink at For this mason,you should insist on the knownquality of
the onceevery five secondrate if the demand for protection Volvo Pentareplacementparts, and should never use par~Is
is very low. If the light is flashing once per second,the of unknownquality.
demandis high and the system is operating at maximum
capacity. The Volvo PentaActive Corrosion Protection Sys- Seeyour Volvo Pentadealer; he can be dependeduponto
tem ;is designedto adequatelyprotect one drive unit from furnish expert service and Volvo Pentaparts.
galvanic corrosion.
In addition to the above, certain parts of the fuel and
Thesystemworksby keepingthe voltage potential in the electrical systemshave beendesignedto complywith U.S.
areaaroundthe drive unit in a rangethat is not corrosive to Coast Guardregulations. Parts or componentswhich corn-
aluminum.This is accomplishedby changing the charge of ply with these regulationsare designedso they will not emit
wate,r moleculesso that they do not removeelectrons from fuel vaporsor causeignition of fuel vaporsin the engine
the drive unit’s metal parts to causecorrosion. compartment. To prevent explosion or fire - DONOT
substitute automotive or general hardwareparts for the
~1 This system will not provide protection from stray following:
currents emitted by a malfunctioning ACpower source on
either your boat, the pier, or other boats in close proximity ¯ Circuit breakers,alternator andrelated wiring.
to yours. Althoughthe zinc sacrificial anodeswill last much
longer with this system, they must still be cleaned and a Starter, starter relay, trim andtilt relay andrelated
checkedfor material condition periodically. wiring.
REPLACEMEttT PARTS ¯ Distributor, distributor cap, spark plugs, high ten,-

sign leadsand related ignition parts.
Your VolvoPentasterndrive wasdesignedfor operating in
a marine environment.This can require operating: ¯ Carburetor,fuel pump,filter and related parts.
¯ At high RPMfor long periods ¯ Rubbercaps (manifold), hoses(water and exhaust~,

and attaching clamps.
¯ In salt and brackish waters
¯ In water laden with silt and minerals
cv..,,.°o 39
OFF-SEASON STORAGE PREPARATIONS Removeflame arrestor. Following instructions on

container, bring engineup to a fast idle and smowly
1. Condition the fuel system: Addfuel Volvo Penta Dura- dispense~ of fogging oil into air intake.
PlusTM Fuel Stabilizer P/N 3855832-6to fuel systemat the
recommended rate stated on the container. This will stabi- ¯ Keepengine running while adding fogging oil.
lize the fuel and prevent the formation of varnish and gumin
the entire fuei system. Run engine under load so fuel ¯ Slow engine, rapidly dispensethe remaining 1/3 of
conditioner reaches all fuet system components.Do this fogging oil and allow engineto quit.
before continuing with the following procedures.
¯ Turn off ignition and replace flame arrestor.
2. Change
motoroil andoil filter:
4. Drain cooling system:Refer to Draining CoolingSystem
Theengineshould first be operatedunder Joaduntil in this section.
the oil is thoroughlywarmed up. If the oil is allowed
to warmup before draining, a morecompletedrain- ¯ Removeall drain plugs and make sure cooling
ing will be accornplished. In addition, the accumu- systemis drained, if needed,insert a small wire or
lated impurities will be held in suspensionby the oil suitable object into drains to ensure openingsare
and be removedduring the draining operation. not blocked.
Remove the motor oil. Refer to Draining and Filling Replace water pumpimpeller every two years.
the EngineCrankcasein this section. Dispose of
used oil in accordancewith any applicable environ- 5. Drain pivot housing:Refer to Draining CoolingSystem
in
mental regulations. this section.

¯ Install a newoil filter end fill the crankcasewith [~ Failure to completely drain the cooling system and
recommended oil. drive unit will result in serious damageto the engine,
exhaust manifolds, and drive unit whentemperatures go
¯ After changingthe motoroil, with drive unit in full belowfreezing. Clear drain openingwith a piece of wire to
downposition, run the engineat a fast idle for a few eliminate any doubt of complete drainage.
minutes to distribute the clean oil through the
engine. Fillthe engine block, exhaustmanifolds, and thermostat
housing with a 50/50 mixture of anti-freeze and water to
[~ Drive unit must be submergedin water or an accesso- provide addedprotection.
ry flushing adaptor must be used while operating engine.
Seeyour Volvo Penta dealer. 6. Change drive unit lubricant: Drain and refill with fresh
Volvo PentaDuraPlusTM GL5 Synthetic GearLube. Refer to
Safety Warning: Whenusing a flushing adaptor, re- Drive Unit Lubrication in this section. Disposeof usedoil in
movethe propeller before starting the engineto prevent accordancewith any applicable environmentalregulations.
accidental contact with movingpropeller. If propeller is not
removed,personalinjury could result. 7. Lubricate gimbal bearing: Refer to External Lubrication
Pointsin this section.
¯ Checkthe oil filter gasketfor leaks.
8. Disconnect the battery and place in storage. When
¯ Shut off the engineandcheckthe oil level. Addoil if storagewill be for a considerablelength of time, periodically
necessaryto bring the oil level up to, but not over, recharge the battery following the manufacturer’s recom-
the full mark. mendations.
3. Fogengine: [~ A discharged battery can be damagedby freezing.
¯ Warmup engine to ensure fuel conditioner is 9. Sprayentire engine and drive unit with a rust preventa-
throughout the fuel system. tive coating, such as Volvo Penta DuraPlusCorrosion Shield
or equivalent, following the directions on the container.
¯ Use1/2 pint (0,25litre) of foggingoil or 12oz. (355
spray can to fog engine. 10. Pump out bilge andlet air dry beforecoveringfor winter
storage. Federal, State or local regulations prohibit the
pumpingof oil into any navigable waters.
0 CV-9825/eng
SPECIFICATIONS
Models 4.3 GL, GS, 5.0 GL & 5.7 GS
Disp,|acement 4.3 GL,GS- 262cu. in. (4,3 litres)
5.0 GL- 305cu. in. (5,0 litres)
5.7 GS- 350cu. in. (5,7 litres)
Bore and Stroke 4.3 GL, GS- 4.000x 3.480 in. (101,60x 88,39rnm)
5.0 GL- 3.740 x 3.480in. (95,00 x 88,39 ram)
5.7 GS- 4.000 x 3.480 in. (101,60 x 88,39 mm)
Numberof Cylinders 4.3 GL, GS- 90° V-6
5.0 GL- 90° V-8
5.7 GS- 90° V-8
Firing Order 4.3 GL,GS- 1-6-5-4-3-2
5.0 GL- 1-8-4-3-6-5-7-2
5.7 GS- 1-8-4-3-6-5-7-2
Full ’Throttle OperatingRange 4.3 GL- 4200-4600RPM

4.3 GS - 4400-4800RPM
5.0 GL - 4400-4800RPM
5.7 GS - 4400-4800RPM
Idle RPM 550-650 RPMin forward gear

Ignition Timing Authorized Volvo Penta dealer service only
Recommended
Spark Plugs Seeyour Volvo Penta dealer
Charging System 65 ampalternator, with internal transistorized voltage regulator
Carburetor Adjustableidle circuit
Fixed mainfuel jets
Electric choke
Fuel Filter Seeyour Volvo Penta dealer
Fuel Filter Location Refer to Modelin Features section
Cooling System Variable volume pumpon engine
Recirculating pumpon engine
Thermostatically controlled temperature
CrankcaseCapacity 4.3 GL,GS- 4.0 quarts(3,8 lives), 4.5 quarts(4,3 litres) with filter
5.0 GL- 5.0 quarts(4,7 iitres), 6.0 quarts(5,7 litres) with filter
5.7 GS- 5.0 quarts(4,7 litres), 6.0 quarts(5,7 litres) with filter
Oil Filter Seeyour Volvo Penta dealer

Oil Filter Location Refer to Modelin Features section
Drive Unit Oil Capacity SX- Approx. 71 oz. (2100 ml)
DP- Approx. 81 oz. (2400 ml)
Volvo Penta DuraPlusTM GL 5 Synthetic Gear Lube
Volvo Penta P/N 3810106-9(U.S. and CanadaOnly)
Volvo Penta P/N 1141572-6(other markets)
Synthetic oil (API GL5 SAE75w/90)
Seeyour Volvo Penta dealer
Continued
SPECIFICATIONS
- (continued)
Models 4.3 GL, GS, 5.0 GL& 5.7 GS
Battery Size 4.3 GL, GS360 Cold Cranking Amp(CCA)rating
5.0 GL - 650 Cold Cranking Amp(CCA)rating
5.7 GS- 650 Cold Cranking Amp(CCA)rating
Volvo PentaMarine ProductsLP reserves t~e right to makechangesin weight, construction, materials or specifications
without notice or obligation.
MAINTENANCE SCHEDULE
Items markedZ~ SafetyWarning,are safety related service points to prevent mechanicalfailures, that could lead to an
injury. Makesure the safety related service is performedat these points and at the intervals specified.
Weekly Every 50
By Operating
Operator Monthly Hours
Anodes(Sacrificial) C {14dys)
Battery and Connections- Water Level C C,T C,T

Belts - Alternator, PowerSteering, WaterPump C,T C,T
Bilge Area - Clean C P

Z~I Boat Safety Equipment C C C
Z~ Emergency
Stop Switch, Clip, and Lanyard C C C
Engine Alignment and Mounting Screws

Engine CrankcaseOil C,F R
EngineOil Filter R
Z~I ExhaustSystemHoses/Clamps
- Leakage C,T C,T
Fasteners- Screws,Nuts, Etc. C,T C,T

Z~ RameArrestor - Mounting C,T
A = Adjust C = Check L = Lubricate F = Fill
P = Perform R = Replace T = Tighten or Torque ¯ = By Dealer
~< = Oncea seasonor every 100 operating hours, whichever comesfirst.
Continued
Z~I Safety Warning:Whenreplacementparts are required, we recommend that you use genuineVolvo Penta service
parts, or parts with equivalentcharacteristics, includingtype, strengthandmaterial. Else of substandard
parts could
result in productfailure andpersonalinjury.
2 CV-9825/eng
MAINTENANCE
SCHEDULE- (continued)
items marked~ Safety Warning,are safety related service points to prevent mechanicalfailures, that could lead to an
injury. Makesure the safety related service is performedat these points and at the intervals specified.
Weekly Every 50
By Operating
Operator Monthly Hours
FuelFilter R
/~, Fuel System- Leakage C,T C,T C,T
Gimbal Bearing
Hull - Clean P
PCVValve C.
PowerSteering - Operation/Fluid C,F C,F
PowerTrim/Tilt - Operation/Fluid C,F C,F

Propeller and Shaft C,L C,L
/~k RemoteControl Shift Cable - Damage C C
/~ Shift System- Operation C C,A*
Spark Plugs R
Z~ SparkPlug Wires/Boots - Deterioration C
Z~ Steering System/Cable- Operation C L L
U-Joint Shaft Splines L:~
U-Joint Bellows C
Drive Unit Oil C,F R
Water Pumpimpeller C R (2 yrs)
A = Adjust C = Check L = Lubricate F = Fill

P = Perform R = Replace T = Tighten or Torque ~< = By Dealer
~<* = Oncea seasonor every 100 operating hours, whichevercomesfirst.
/~k Safety Warning:Whenreplacementparts are required, we recommend that you use genuineVolvo Penta service
parts, or parts with equivalentcharacteristics, includingtype, strengthandmaterial. Useof substandard
parts coukJ
result in productfailure andpersonalinjury.

Volvo 4.3all - OperatingManual

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Volvo 4.3all - OperatingManual

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Owner’s Manual

Whetheryour Volvo Penta stern drive is used to power a

Wewish you pleasant trips with your boat.

Engine Model No. Serial No.

Transom Shield Model No. Serial No.

Drive Unit Model No. Serial No.

Ignition Key No. RecommendedPropeller Size

Boat Model No. Hull Identification No. (HIN)

GENERAL INFORMATION FEATURES

;FUEL AND LUBRICATION STARTING AND OPERATION

SPECIFICATIONS AND MAINTENANCE

THIS PRODUCT MAY BE SERVICED BY ANY AUTHORIZED

CV -9825/eng Printed in the U.S.A.

Basic Safety Rules of Boating .................. 3 Repair Service .............................. 3

SAFETY Recordeach of these numbersin the spaces provided on

Whenyou purchased your boat, the dealer wasrequired

BOATER’S RESPONSIBILITIES MODEL AND SERIAL NUMBERS

emergency.Requirementsfor personal flotation devices serial numbers.

[~ The model and serial numbersfor the drive unit are

Contents under pressure

"Position Indicator" Symbols

Voltmeter (~ Fuel filter

Water temperatu re A Emergency stop Oil pressure

~,~ o Use gasoline

Circuit Breakers and Fuses ..................... 9 Power Trim/Tilt .............................. 5

POWERTRIM/TILT IMPACT PROTECTION

,J Maintainsboat on plane at reducedthrottle settings

item Description Page j kem Description Page

iNSTRUMENTS Usingthis switch is simple and should not interfere with

SACRIFICIALANODES Boats that connect to an ACpowersource (shore power)

or REVERSE at idle speedand determine if the boat moves

Drive Unit Lubrication ....................... 13 Oil Identification Symbol..................... 12

GASOLINE REQUIREMENTS To prevent gum formation and corrosion in the fuel

DR¢68~ DR1563 DRC6833

FUEL AND LUBRICATION

POWERTRIM/TILT FLUID LEVEL POWERSTEERING FLUID LEVEL

~ Level should be between the "MIN" and "MAX"

DRIVE UNIT LUBRICATION

Thedrive unit is filled at the factory with Volvo Penta

GIMBAL BEARING LUBRICATION

SeeExternal Lubrication Points in Specifications and Main-

Before Starting ............................. 15 Preparation for Boating After Storage ........... 14

STARTING AND OPERATION

gage button ©. ate the blower as recommended by the boat manufacturer

Binn=¢le MountControl 2. Checkthe bilge for excessivewater accumulation.Always

2. Movecontrol handle FORWARD

STARTING COLD ENGINE HOW TO SHIFT AND CONTROL SPEED

1. Movecontrol handle to the NEUTRAL

STOPPING ENGINE 3. Watchthe enginetemperature

~] Do not stop engine at speeds above idle or "speed First TwoHours

2. Watchthe oil pressuregauge.If the indicator fluctuates Final TenHours

STARTING AND OPERATION

OPERATION AFTER BREAK-IN POWERTRIM/TILT SWITCH OPERATION

STARTING AND OPERATION

the drive unit is in the tilt range.

SHALLOW WATER OPERATION If the power steering system becomesinoperative, .~n

HIGH ALTITUDE OPERATION Usingthe port enginethat doesnot havethe function-

STARTING AND OPERATION

PROPELLER SELECTION If using D-series aluminumpropeller sets, you must

also use an In-Trim Limiter Kit, P/N 3857598-1,available

Active Corrosion Protection System............. 3g Engine Submersion ......................... 28

ELECTRICAL SYSTEM Z~ Safety Warning:

Theengine’s electrical systemfeatures cranking, charg- ¯ Do not exposebattery to electrical sparksor an