ILMOR One-Drive Owner's Manual
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ILMOR One-Drive Owner's Manual

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M A R I N E E N G I N E S
ONE-DRIVE
OWNER'S
MANUAL

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Summary of Contents for ILMOR One-Drive

  • Page 1 M A R I N E E N G I N E S ONE-DRIVE OWNER’S MANUAL...
  • Page 2 No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without written permission. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 3 Ilmor stern-drives are designed for a wide range of applications and are designed to reduce vibration and make your cruising more pleasurable. To help you enjoy your Ilmor Marine products for many years to come, please follow these recommendations: • Read and understand this Owner’s Manual before you operate your vessel to ensure that safe operating practices and maintenance procedures are followed.

  • Page 4: Record Of Ownership

    Date Purchased: ______________________________________________ Engine Model: _______________________________________________ Engine Horsepower: __________________________________________ Propeller Number: ____________________________________________ Propeller Pitch: ______________________________________________ Propeller Diameter: ___________________________________________ Hull Identification Number (HIN): ______________________________ Boat Manufacturer: ___________________________________________ Boat Model: _________________________________________________ Dealer: _____________________________________________________ Dealer Phone: ________________________________________________ © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 5: Table Of Contents

    STERN-DRIVE OPERATION ..........3-1 PROPELLER SELECTION ..............3-1 INSTALLING THE PROPELLERS ............3-2 REMOVING THE PROPELLER ............3-3 DAILY CHECKS ..................3-4 Visual Checks ..................3-4 Check the Stern-Drive Oil Level ............3-4 Check the Power Trim Pump Fluid ..........3-7 © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 6 The Importance of Periodic Maintenance ........4-1 Performing Periodic Maintenance ...........4-1 The Importance of Daily Checks ............4-1 Ilmor Replacement Parts ..............4-1 Tools Required ...................4-2 Ask Your Authorized Ilmor Marine Dealer or Distributor for Help ....................4-2 TIGHTENING FASTENERS ..............4-2 TORQUE CHARTS .................4-2 Standard Torque Values ..............4-2 Torque Specifications .................4-2...

  • Page 7: Safety

    Section 1 SAFETY Ilmor considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Ilmor products, exercise care, common sense and comply with the safety information in this manual and on the engine and stern-drive’s safety labels.

  • Page 8: Safety Precautions

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • Consult your authorized Ilmor Marine dealer or distributor for additional training. During Operation and Maintenance A DANGER! FIRE HAZARD! Ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operation.
  • Page 9 • Stop the engine before you begin to service the stern-drive and secure the propeller so it will not turn. WARNING! ALCOHOL AND DRUG HAZARD! Never operate the engine while under the influence of alcohol or drugs or when feeling ill. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 10 Always install wire cages on portable safety lamps. A CAUTION! TOOL HAZARD! Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 11 Always tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly. NOTICE: Only use replacement parts specified. Other replacement parts may affect warranty coverage. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 12 This will keep the anodes in the water and will keep the exhaust pipe engaged with the exhaust port of the drive. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 13: Product Overview

    • Perform all safety checks as necessary to ensure safe operation; • Comply with and follow all lubrication and maintenance instructions and recommendations; and • Have an authorized Ilmor Marine dealer/distributor perform periodic checkups. Conducting normal maintenance service and replacing consumable parts...

  • Page 14: Dealer/Distributor Responsibilities

    In general, a dealer’s responsibilities to the customer include predelivery inspection and preparation such as: • Ensure that the vessel is properly equipped. • Prior to delivery, make certain that the Ilmor stern-drive and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency.

  • Page 15: Location Of Serial Numbers

    PRODUCT OVERVIEW Location of Serial Numbers The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your Ilmor stern-drive. When contacting Ilmor about service, always specify model and serial numbers. Transom assembly serial number Drive unit...

  • Page 16: Corrosion Protection

    To help control the effects of galvanic corrosion, Ilmor Marine One-Drive stern-drives come with several anodes and an electronic anticorrosion system (I-CaPS) that protect the stern-drive in moderate corrosive conditions.

  • Page 17: Shore Power

    Galvanic isolators are available from the aftermarket (not supplied by Ilmor) to block these currents while still providing a path to ground for dangerous shock currents.

  • Page 18: Additional Protection

    Trim cylinder anodes I-CaPS electrode Gear Ventilation housing plate anode anodic plates Propeller shaft anodes Figure 2-3 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 19: Gear Housing Anodic Plates

    The ventilation plate anode (Figure 2-5, 1) is installed on the front of the drive shaft housing on top of the ventilation plate. Figure 2-5 Trim Cylinder Anodes The trim cylinder anodes (Figure 2-6, 1) are installed on each trim cylinder. Figure 2-6 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 20: Propeller Shaft Anode

    SECTION 2 ILMOR ONE-DRIVE OWNER’S MANUAL Propeller Shaft Anode The propeller shaft anode (Figure 2-7, 1) is located behind the aft propeller. Figure 2-7 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 21: Features And Controls

    FEATURES AND CONTROLS Remote Controls The Ilmor One-Drive can be controlled mechanically with push-pull cables or electronically. Please refer to the Ilmor Engine Operation Manual or the Electronic Control System Operation Manual (if so equipped). Power Trim The power trim is used to accelerate the vessel onto plane, reach the desired engine rpm or vessel speed, and improve the performance of the vessel when there is a change in water or boating conditions.

  • Page 22: Stern-Drive Trim Angle

    A CAUTION! Always raise and lower dual stern-drives evenly together. Damage to the tie bar connecting the two stern-drives together could result from twisting or binding if the stern-drives are raised or lowered separately. 2-10 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 23: Electrical System

    Figure 2-9 Ilmor Cathodic Protection System The Ilmor Cathodic Protection System (I-CaPS) has a 20 A in-line fuse (Figure 2-10) in the wire which connects to the positive (+) terminal on the controller. If the fuse blows, the system will not operate resulting in a loss of corrosion protection.

  • Page 24: Stern-Drive Operation

    Keep these guidelines in mind when selecting a propeller: • Your Ilmor Marine dealer or distributor is most qualified to help you select a propeller. NOTICE: Never attempt to change propellers until after determining the average load and individual requirements.

  • Page 25: Installing The Propellers

    STERN-DRIVE OPERATION Problems associated with propellers include ventilation, cavitation and blow-out. These problems have similar symptoms and are best diagnosed by an expert. If a propeller related problem develops, consult your Ilmor Marine dealer or distributor. INSTALLING THE PROPELLERS 1. Rear propeller nut 5.

  • Page 26: Removing The Propeller

    3. Slide the propeller and the thrust hub off the propeller shaft. 4. Turn the front propeller nut (70 mm [2-3/4 in.]) counterclockwise to remove the nut. 5. Slide the propeller and the thrust hub off the propeller shaft. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 27: Daily Checks

    Gear Lube * Quick Silver is a registered trademark of Brunswick Corporation. NOTE: The oil level will rise and fall during operation. Check the oil level before starting, when the engine is cold. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 28 NOTICE: If more than 60 ml (2 fl oz) of gear oil is required to fill the reservoir, a seal may be leaking. Damage to the stern-drive may occur because of lack of lubrication. Consult your authorized Ilmor Marine dealer or distributor.
  • Page 29 * Quick Silver is a registered trademark of Brunswick Corporation. 3. When replacing the cap, ensure that the rubber gasket is inside the oil reservoir cap and install the cap. Do not over-tighten. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 30: Check The Power Trim Pump Fluid

    1. Place the stern-drive in full DOWN/TRIM-IN position. 2. Observe the oil level in the reservoir. The oil level should be maintained within the MIN and MAX lines (Figure 3-4, 2) on the reservoir (Figure 3-4, 1). Figure 3-4 © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 31 Fill the Power Trim Pump Fluid NOTE: The power trim fluid does not require changing unless it becomes contaminated with water or debris. Consult your authorized Ilmor Marine dealer or distributor if the power trim fluid needs to be changed.
  • Page 32 ILMOR ONE-DRIVE OWNER’S MANUAL 3. Add oil to bring the oil level to within the MIN and MAX lines on the reservoir (Figure 3-6, 2). Figure 3-6 4. Install the fill cap assembly. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 33: Maintenance

    MAINTENANCE This section of the Owner’s Manual describes the procedures for proper care and maintenance of the stern-drive. Before you operate the One-Drive, read the following safety information and review Safety on page 1-1. PERIODIC MAINTENANCE A CAUTION! Establish a periodic maintenance plan according to the stern-drive application and make sure to perform the required periodic maintenance at the intervals indicated.

  • Page 34: Tools Required

    Before starting any periodic maintenance procedure, make sure to have the tools needed to perform all of the required tasks on hand. Ask Your Authorized Ilmor Marine Dealer or Distributor for Help Our professional service technicians have the expertise and skills to help with any maintenance or service related procedures.

  • Page 35: Periodic Maintenance Table

    MAINTENANCE PERIODIC MAINTENANCE TABLE ¡: Check or clean ¯: Replace : Consult your authorized Ilmor Marine dealer or distributor Daily Every Every Every Every See Daily Checks Weekly Year on page 3-4 Hours Hours Hours Check the stern-drive oil level...

  • Page 36: General Inspection

    SECTION 4 ILMOR ONE-DRIVE OWNER’S MANUAL ¡: Check or clean ¯: Replace : Consult your authorized Ilmor Marine dealer or distributor Daily Every Every Every Every See Daily Checks Weekly Year on page 3-4 Hours Hours Hours Lubricate the cables and the ¡...

  • Page 37: Power Trim Pump Fluid

    MAINTENANCE POWER TRIM PUMP FLUID Power trim fluid does not require changing unless it becomes contaminated with water or debris. Consult your authorized Ilmor Marine dealer or distributor if the power trim fluid needs to be changed. PERIODIC MAINTENANCE PROCEDURES Weekly Perform the following procedures on a weekly basis.

  • Page 38: After Initial 50 Hours Of Operation

    Where used Multi-purpose heavy-duty type lithium grease, Coupler NLGI #2 NOTE: Lubricate the coupler on the One-Drive model every 50 hours if the vessel is operated at idle for prolonged periods of time. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 39: Every 50 Hours Of Operation

    • Lubricating the cable and the linkages Lubricating the Propeller Shaft and Retorquing the Nut If operating in only freshwater, this maintenance may be extended to every four months. See Installing the Propellers on page 3-2. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 40 Inspecting the Bellows and the Clamps See General Inspection on page 4-4. Checking the Engine Alignment Consult your authorized Ilmor Marine dealer or distributor. Lubricating the Steering Shaft Bushing Apply approximately 8 to 10 pumps of grease to the steering shaft bushing grease fitting (Figure 4-4, 1).
  • Page 41 Check the electrical connections and leads for damage and corrosion. Testing the I-CaPS Unit Output See Ilmor Cathodic Protection System on page 2-11. Checking the Steering System for Loose, Missing or Damaged Parts Check the steering system and tighten any loose parts, replace any missing or damaged parts.
  • Page 42 Urea grease water resistant type, NLGI #2 Steering cable 3. Lubricate the steering system clevis pin (Figure 4-7, 1). Figure 4-7 Description Where used Urea grease water resistant type, NLGI #2 Clevis pin 4-10 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 43: Every 150 Hours Of Operation

    If using copper- or tin- based anti-fouling paint, avoid an electrical interconnection between the Ilmor Product, anodic blocks, or I-CaPS and the paint by allowing a minimum of 40 mm (1-1/2 in.) of UNPAINTED area on the transom of the vessel and around these items.
  • Page 44 Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as lubrication oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. 4-12 © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 45 5. Remove the oil fill/drain plug (Figure 4-10, 1) and gasket (Figure 4-10, 2). 6. Drain the oil. Figure 4-10 7. Remove the oil vent plug (Figure 4-11, 1) and gasket (Figure 4-11, 2). Allow the oil to drain completely. Figure 4-11 4-13 © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 46 NOTICE: If any water drains from the oil fill/drain hole, or if it appears milky, the stern-drive may be leaking and should be checked immediately by your authorized Ilmor Marine dealer or distributor. 8. Remove the case plate cover (Figure 4-12, 4), filter cover (Figure 4-12, 3), magnet (Figure 4-12, 2) and filter (Figure 4-12, 1).
  • Page 47 16. Check the oil level in the oil reservoir after first use. 17. Check the stern-drive oil level within one week of the first use as follows: a. Remove the oil vent plug (Figure 4-14, 1) and gasket (Figure 4-14, 2). Figure 4-14 4-15 © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 48 This will prevent oil leaks from the reservoir tank. Figure 4-15 Remove the drive unit and lubricate the universal-joint shaft splines (Figure 4-16, 1) and the O-rings (Figure 4-16, 2). Figure 4-16 4-16 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 49: Every 1000 Hours Of Operation

    Perform the following maintenance every 1000 hours of operation. • Replace of friction disc (Light duty commercial applications only) Replace of Friction Disc (Light Duty Commercial Applications Only) Consult your authorized Ilmor Marine dealer or distributor. 4-17 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 50: Every Year

    See Lubricating the Steering Shaft Bushing on page 4-8. Lubricating the Unit Bearing (Gimbal Housing) See Lubricating the Unit Bearing (Gimbal Housing) on page 4-9. Lubricating the Engine Coupler See Lubricating the Engine Coupler on page 4-6. 4-18 © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 51: Every 2 Years

    See Checking the Circuit for Loose or Damaged Connections on page 4-9. Testing the I-CaPS Unit Output See Ilmor Cathodic Protection System on page 2-11. Checking the Steering System for Loose, Missing or Damaged Parts See Checking the Steering System for Loose, Missing or Damaged Parts on page 4-9.

  • Page 52: Troubleshooting

    If any are parts. loose or missing, consult your authorized Ilmor Marine dealer or distributor immediately. Contaminated power Consult your authorized steering fluid. Ilmor Marine dealer or – distributor. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 53 Trim pump oil level is Fill pump with oil. operate (Electric motor low. operates but stern-drive Stern-drive binding in Check for obstruction. does not move) gimbal ring. Consult your authorized – Ilmor Marine dealer or distributor. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 54: Long-Term Storage

    LONG-TERM STORAGE COLD WEATHER (FREEZING TEMPERATURE), SEASONAL AND EXTENDED STORAGE NOTICE: Ilmor strongly recommends that this service be performed by an authorized Ilmor Marine dealer or distributor. Damage caused by freezing is not covered by the Ilmor warranty. Stern-Drive Lay Up 1.

  • Page 55: Stern-Drive Recommissioning

    LONG-TERM STORAGE Stern-Drive Recommissioning 1. Carefully inspect the stern-drive for leaks. 2. Check the steering system, shift and throttle control for proper operation. © 6/2016 Ilmor Marine Engines, Version 1.0...

  • Page 56: Specifications

    Automatic transmission fluid Dextron III Tilt/trim system Automatic transmission fluid Clutch system Hydraulic multi-friction disc type with hydraulic pump Shift type Electrical shift with solenoid Power steering system Mechanical cable operated hydraulic power assist © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 57 (weight) * Quick Silver is a registered trademark of Brunswick Corporation. NOTE: For engine/stern-drive performance, electrical, outline, piping diagrams and related information, see the engine-specific section of Installation Manual and/or the Service Manual. © 6/2016 Ilmor Marine Engines, Version 1.0...
  • Page 60 186 PENSKE WAY MOORESVILLE, NC 28115 844-GO-ILMOR (464-5667) FAX (704) 360-1901 WWW.ILMOR.COM P/N 500-0092A PRINTED IN U.S.A.

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