Crusader 5.7L Carburetor Owner's Operation And Maintenance Manual
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Crusader 5.7L Carburetor Owner's Operation And Maintenance Manual

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OWNER'S OPERATION
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MAINTENANCE MANUAL
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  • Page 1 OWNER’S OPERATION MAINTENANCE MANUAL A Division of...
  • Page 2 The descriptions and specifi cations contained in this manual were in effect at the time of printing. Crusader Marine Engines’ policy of continued improvement reserves the right to change specifi cations or design without notice and without obligation.

  • Page 3: Table Of Contents

    ........................Safety Information ..................Replacement Parts ................................Safety Warnings ................. Crusader Marine Engines’ Commitment to You ....Owner Warranty Registration (Warranty Registration Card is located at the back of this manual) ......................Engine Operation and Care ......................... Maintenance Records ........................
  • Page 4 TABLE OF CONTENTS ................. 5 - CONDITIONS AFFECTING OPERATION ....................... Trim and Weight Distribution ..........................Boat Bottom ........................Propeller Selection ....................6 - ENGINE BREAK-IN PERIOD .................... 7 - 25-HOUR ENGINE INSPECTION ....................8 - FUEL REQUIREMENTS 31-32 ......................Gasoline Requirements .......................

  • Page 5: L510019-05

    TABLE OF CONTENTS ..................... 11 - ENGINE SPECIFICATIONS 55-56 ..................12 - OUT-OF-SEASON STORAGE 57-61 ........................Engine Storage ........................Draining Instructions ........................Battery Storage ....................Out-Of-Season Engine Warm-Up ....................Recommissioning After Storage 59-60 ....................13 - TROUBLESHOOTING 61-64 ....................14 - WATER FLOW DIAGRAM ................

  • Page 6: Service And Warranty

    “common sense” explosion hazard and should be avoided. operation, are major accident prevention measures. Always request that genuine Crusader Marine Engines replacement parts be used in any repairs or maintenance being performed on your engine(s). SAFETY WARNINGS DANGER Signals serious damage, failure or breakdown of equipment;...

  • Page 7: Crusader Marine Engines' Commitment To You

    CRUSADER MARINE ENGINES’ COMMITMENT TO YOU Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine. Your Dealer also wants you to be completely satisfi ed, and invites you to return for all your servicing needs, both during and after the warranty period.

  • Page 8: Engine Operation And Care

    ENGINE OPERATION AND CARE Considering the investment that you have made in your new Crusader engine(s), we know you will want to operate and maintain it properly. We urge you to follow the maintenance instructions contained in your engine’s “Operation and Maintenance Manual.”...

  • Page 9: Replacement Parts Inquiries

    Only authorized distributors can purchase parts from the factory. Crusader Marine Engines does not sell to unauthorized dealers or retail customers. When checking on parts, the dealer will require the engine model and serial number to order the correct parts.

  • Page 10: Crusader Marine Engines One-Year Limited Warranty (For Engines Sold And Used In The United States And Canada)

    Crusader will arrange for the correction of all defects under this Limited Warranty to be made free of charge at the selling dealership or an authorized Crusader service center. Crusader, in its discretion, may provide for the repair or replacement of any defective part at Crusader’s facility.
  • Page 11 Any owner/user hereby waives for himself/herself/itself and his/her/its successors and assigns (a) any and all claims for punitive damages, and (b) all claims of negligence or strict liability or both. In no event will Crusader’s liability exceed the purchase price of the Products which is actually paid to Crusader.

  • Page 12: Items Not Covered Under The Limited Warranty

    • Repairs made necessary by normal wear, rust, electrolysis or corrosion, or by the use of the parts or accessories which are either incompatible with the Crusader product or adversely affect its operation, performance or durability. •...

  • Page 13: Things You Should Know About The Warranty

    Production Changes Crusader Marine Engines and its Distributors reserve the right to make changes in the engines built and/or sold by it at any time without incurring any obligation to make the same or similar changes on engines previously built and/or sold.

  • Page 14: Marine Transmissions

    Crusader Marine Engines are equipped with transmissions designed, built and warranted by other manufacturers. Although much of the transmission warranty is handled through Crusader Marine Engines, there may be issues for which, you, the owner, may want to contact the transmission manufacturer directly. The transmission suppliers are listed below for your reference.

  • Page 15: Resolving A Service Problem

    RESOLVING A SERVICE PROBLEM Your satisfaction and faith in the product are of major importance to your dealer and to Crusader Marine Engines. Any problems with service, warranty or operation of your Crusader powered boat will be resolved by your dealer. He should be your primary source of information on your boat.

  • Page 16: Crusader Master Distributors

    SERVICE and WARRANTY - 1 CRUSADER MARINE ENGINES DISTRIBUTORS Marysville Marine Engine Distributors Inc. 400 University Court Blackwood, NJ 08012 Jaime Cummins Engine Phone: 800-220-2700 Distributors Fax: 856-228-5657 - Parts Engine Fax: 856-228-5531 - Sales Distributors II Trans Pacific Engine Distributors Inc. II Engine Distributors - 303 Interstate Dr.

  • Page 17: Dealers Responsibilities

    In general, the dealer’s responsibilities to you, the customer, include pre-delivery inspection and preparation such as: • Make sure that the boat is properly equipped • Prior to delivery, make certain that the Crusader Engine is in proper operating condition • Make all necessary adjustments for maximum effi ciency •...

  • Page 18: Transferable Warranty

    The second owner can be registered as the new owner, and may retain the unused portion of the limited warranty. The forms and instructions necessary to transfer the unused portion of the Crusader One year Limited Warranty are provided in Forms, section 17 of this manual.

  • Page 19: Notes

    SERVICE and WARRANTY - 1 L510019-05...

  • Page 20: Boating Responsibility

    BOATING RESPONSIBILITIES - 2 CARBON MONOXIDE HAZARD To fi nd out more about making boating safer, including how you can prevent carbon monoxide poisoning on recreational boats, contact: DANGER National Marine Manufacturers Association Carbon Monoxide (CO) is a colorless, odorless 200 East Randolph Drive and tasteless gas.

  • Page 21: Safe Boating Suggestions

    Crusader engine. When service and maintenance • Know your boat’s loading and operating are required, return to your authorized Crusader Marine limitations. DO NOT OVERLOAD! Engines Dealer. • Make periodic checks of safety equipment onboard.

  • Page 22: Rules Of The Road

    BOATING RESPONSIBILITIES - 2 RULES OF THE ROAD Boat Capacity • Load only to manufacturer’s specifi cations Channel Buoy Guide • Distribute load evenly; keep it low • Passengers should only ride on the parts of the The color of the paint is the only characteristic which boat that are designed for that purpose has the same meaning on all buoys.

  • Page 23: Engine Identification

    ENGINE IDENTIFICATION - 3 ENGINE IDENTIFICATION 5.7L Important! See your Owners Manual to insure that specifications for your engine have not changed or been omitted from the specifications listed. When ordering service parts or obtaining information, FUEL RECOMMENDATIONS Unleaded 89 (R+M) / 2 Octane Minimum) always give the engine model and the serial number.

  • Page 24: 2004 Model Identifi Cation / Advisory

    2004 MODEL IDENTIFICATION / ADVISORY MODEL C X L X H F L 245 M SERIAL 641254 Space: MANUFACTURER C - Crusader Spaces: DRIVE GEAR RATIO OR REDUCTION The drive gear ratio will appear in these spaces Space: FACTORY FRESHWATER / CLOSED COOLING which identifi...

  • Page 25: Operating Instructions

    OPERATING INSTRUCTIONS - 4 INSTRUMENTATION 4. Oil Pressure Gauge - indicates the engine oil Boat manufacturers install many different types of pressure instrumentation on boats. Become familiar with the instrumentation on your boat and be aware of abnormal 5. Voltmeter - indicates the battery voltage and operating conditions.

  • Page 26: Engine Alarm System

    OPERATING INSTRUCTIONS - 4 ENGINE ALARM SYSTEM REMOTE CONTROLS Crusader Marine Engines come equipped with a Your boat may be equipped with one of many different provision for an audible and/or visual engine alarm types of remote controls available. Ask you dealer for system.

  • Page 27: Starting Engine

    OPERATING INSTRUCTIONS - 4 STARTING ENGINE WARNING Before starting engine, ventilate the engine Check for compartment by operating the bilge blower for a Check for signs of minimum of fi ve minutes to remove any gas fumes signs of external leaks external leaks from engine compartment.

  • Page 28: Shifting Transmission

    3. Move the transmission lever completely NOTICE: If engine still fails to start, contact your backward to shift into Reverse gear. Crusader Marine Engines Dealer for service. 4. Move the transmission lever to the center detent 7. Check engine oil pressure immediately after position to shift into Neutral.

  • Page 29: Stopping Engine

    OPERATING INSTRUCTIONS - 4 STOPPING ENGINE FREEZING TEMPERATURE OPERATION When returning to the dock, or whenever stopping the If the possibility of freezing exists, the cooling system engine, bring the throttle back to the idle position. After must be protected after the engine is shut off to prevent the engine reaches idle speed, turn the ignition key to freeze damage to the engine.

  • Page 30: Conditions Affecting Operation

    In most areas, it is advisable to coat the boat bottom with under the Crusader Warranty. antifouling paint to prevent the build-up of marine growth. Contact your dealer for advice on these requirements in your area.

  • Page 31: Engine Break-In Period

    • After the engine is thoroughly warmed up, and NOTICE: Crusader Marine Engines assumes no the boat is underway, open the throttle to wide responsibility for the costs related to the 25-hour open throttle until maximum RPM is reached.

  • Page 32: 25-Hour Engine Inspection

    Cooling System - Inspect all the hoses for leaks, that the engine be given an inspection. Your boat dealer damage and deterioration. Check all the hose or a Crusader servicing dealer should be contacted clamps for adequate tightness. to perform the necessary checks and adjustments to ensure the proper engine performance.

  • Page 33: Fuel Requirements

    Such damage is not covered by the Crusader Marine Engines warranty. • Hard starting and operating diffi culties (vapor...

  • Page 34: Piston Damage Due To Detonation And/Or Pre-Ignition

    FUEL REQUIREMENTS - 8 • Operating twin engine boat on one engine at high PISTON DAMAGE DUE TO DETONATION AND throttle setting resulting in overload. /OR PRE-IGNITION • Operating engine with dead cylinder, out of WARRANTY NOTICE: Engine failure due to detonation proper tune or wired with improper fi...

  • Page 35: Oil Requirements

    Crankcase oil and oil fi lter change - Recommended added to the engine oil by the customer are unnecessary intervals: and may be harmful. Crusader Marine Engines does not review, approve or recommend such products. • Initial oil change - 1st 60 days or 25 hours of operation, whichever occurs fi...

  • Page 36: Engine Maintenance

    Some procedures may Dipstick be performed by the owner/operator while others should Tube be performed by an authorized Crusader Marine Engines Dealer. Before performing any maintenance or repair procedure not covered in this manual, it is strongly Dipstick...
  • Page 37 CAUTION Do not attempt to remove the transmission dipstick while the engine is running. Hot transmission fl uid Crusader Marine Engines uses marine transmissions could be sprayed from the dipstick hole. supplied by several manufacturers. The maintenance requirements can be different between 2.

  • Page 38: Lubrication

    ENGINE MAINTENANCE - 10 LUBRICATION Shift Cable Lubricate pivot points and exposed cable (Figure 10-5) Throttle Cable with SAE 30W-30 engine oil. Lubricate pivot points and exposed cable (Figure 10-3) with SAE 30W-30 engine oil. BALL JOINT LUBRICATION CABLE CLIP POINTS LUBRICATION Figure 10-5 Typical Shift Cable...

  • Page 39: Electrical System Circuit Breaker

    ELECTRICAL SYSTEM FUSES The electrical system wiring and connectors should be Crusader engines utilize a fuse to protect the fuel pump. checked periodically for loose or dirty connections and The fuse is mounted in the main engine harness, in damaged wiring.

  • Page 40: Battery

    Remove and check condition of zinc pencil supplied by the battery manufacturer. If this information every 30 days. Replace if more than 50% missing with Crusader Part #10972. P/N 23627 is not available, follow these guidelines for the proper battery care.

  • Page 41: Checking Coolant Level

    ENGINE MAINTENANCE - 10 CHECKING COOLANT LEVEL CAUTION WARNING Do not operate the engine without water being supplied to the sea-water pump. The sea-water Do not remove cooling system fi ller cap when pump impeller may be damaged and subsequent the engine is hot.

  • Page 42: Testing Coolant For Alkalinity

    ENGINE MAINTENANCE - 10 TESTING COOLANT FOR ALKALINITY DRAINING FRESH-WATER COOLING SYSTEM It is recommended that the coolant in the fresh-water WARNING section be tested each year for alkalinity. Coolant Do not remove cooling system fi ller cap when that is not alkaline has lost the effectiveness of its the engine is hot.

  • Page 43: Filling Fresh-Water Cooling System

    ENGINE MAINTENANCE - 10 FILLING FRESH-WATER COOLING SYSTEM 4. Start the engine and operate at idle speed (800-1000 RPM) to purge any air from the A new extended life engine coolant known as DEX- system. When the coolant level remains COOL™...

  • Page 44: Cleaning Sea-Water Section Of Heat Exchanger (Fresh-Water Cooled Applications Only)

    ENGINE MAINTENANCE - 10 CLEANING SEA-WATER SECTION OF HEAT HEAT EXCHANGER - FRESH-WATER COOLED EXCHANGER MODELS ONLY THERMOSTAT The sea-water section of the heat exchanger should HOUSING be cleaned whenever there is a noticeable decrease in cooling effi ciency. You may use the following procedure for cleaning, or, if the build-up of scale and mineral deposits is heavy, it is recommended that the heat exchanger be removed and taken to a repair facility to be...

  • Page 45: Fuel System Description

    ELECTRIC FUEL PUMP Loosen the screw(s) securing the fl ame arrestor cover Crusader Marine Engines are equipped with an electric and fl ame arrestor to the carburetor. Remove the fuel pump mounted on the front right side of the engine, fl...
  • Page 46 Circulation Raw Water Pump Pump 5.7L ACCESSORY DRIVE BELT The Crusader 5.7L engine uses a single serpentine belt Alternator to drive the engine water circulation pump, sea-water pump and the alternator. Crankshaft Pulley Serpentine Belt (LH Rotation) P/N - R066028 Serpentine Belt (RH Rotation) P/N - R066029A Figure 10-16A 5.7L Accessory Drive Belt Confi...

  • Page 47: Changing Oils

    ENGINE MAINTENANCE - 10 CHANGING OILS 3. Coat the sealing ring, on the new fi lter, with a light coating of clean engine oil. Install the oil fi lter securely by hand. DO NOT overtighten. WARNING 4. Fill the engine with the recommended oil, see OIL IMPORTANT: The Federal Water Pollution Control REQUIREMENTS, through the oil fi...

  • Page 48: Engine Alignment

    ENGINE MAINTENANCE - 10 ENGINE ALIGNMENT CAUTION Engine must be properly aligned, or vibration, noise and damage to the transmission output shaft, oil seal and bearings may result. IMPORTANT: On boats with remote “V” -Drives, refer to the “V”-Drive manufacturer’s instructions for the correct alignment of the drive shaft between the “V”...
  • Page 49 ENGINE MAINTENANCE - 10 .003 INCH (0.07 mm) TRANSMISSION FEELER GAUGE OUTPUT FLANGE PROPELLER SHAFT COUPLING FLANGE STRAIGHT EDGE Figure 10-22 Centering Prop Shaft Figure 10-23 Angular Alignment 4. OFFSET ALIGNMENT: If the coupling center lines are not aligned, adjust the engine mounts as follows: •...
  • Page 50 ENGINE MAINTENANCE - 10 IMPORTANT: Angular misalignment conditions may require adjustment of one front mount, both front mounts, trunnions, or any combination. Figure 10-26, Angular Alignment Check, and the following table will assist in the alignment process. ANGULAR MOUNT MISALIGNMENT ADJUST LOWER “A”...
  • Page 51 ENGINE MAINTENANCE - 10 6. After the engine has been properly aligned, secure the engine mounts. 7. Connect the propeller shaft coupling to the transmission coupling. Tighten the coupling attaching bolts and nuts to the correct specifi cations. FASTENER TORQUE SPECIFICATIONS Lb-Ft (N .

  • Page 52: Engine Maintenance Log

    ENGINE MAINTENANCE - 10 ENGINE MAINTENANCE LOG Operating Date Maintenance/Repair Hours L510019-05...

  • Page 53: Maintenance Schedule

    ENGINE MAINTENANCE - 10 MAINTENANCE SCHEDULE After 1st Every 50 Every 100 Location and Service Check 25 Hrs of Hours of Hours of Once Daily Operation Operation Operation Each Year Check coolant level - Fresh-water cooled models only Check oil level - Engine crankcase Check oil level - Transmission Engine Assembly (complete - Check for obvious leaks (water, oil, fuel and exhaust)

  • Page 54: Maintenance Schedule

    (C) All Velvet “V” Drive transmissions - Use Dexron III automatic transmission fl uid All Walters “V” Drive transmissions - Use Exxon Spartan EP-68 or SAE 30 engine oil All Crusader “V” Drive transmissions - Use SAE 80W-90 gear oil (D) Use WD-40 penetration oil or equivalent L510019-05...

  • Page 55: Visual Inspection

    Touch up scratches, nicks and corrosion damage to the exterior fi nish of the engine. Spray paint may be obtained from your local Crusader Marine Engines dealer. Protect engine fi nish from corrosion by periodically spraying the engine exterior fi nish with a rust preventative oil (such as WD-40).

  • Page 56: Filter Requirements

    ENGINE MAINTENANCE - 10 FILTER REQUIREMENTS Description Part No. Oil Filter (remote-mounted) 22679 Water Separator/Fuel Filter See Dealer ON-BOARD PARTS KITS Description Part No. ON-BOARD PARTS KIT 5.7L (LH) ‘04 SERPENTINE RK173094 Box, On-Board 22433 Belt, Serpentine R066028 Coil, Ignition Breakerless R117004 Resistor, Ignition R119001...

  • Page 57: Engine Specifications

    ENGINE SPECIFICATIONS - 11 ENGINE SPECIFICATIONS MODEL 5.7L (Horsepower) (300 HP - Carburetor) Displacement 5.7L (350 CID) Bore 4.0 in. (101.6 mm) Stroke 3.48 in. (88.3 mm) Compression Ratio 9.4:1 Compression Pressure 130 - 215 psi (896 - 1482 kPa) WOT Operating RPM 4800 - 5200 Cruising RPM (Max)
  • Page 58 ENGINE SPECIFICATIONS - 11 5.7 Liter 5.7 Liter RH ROTATION LH ROTATION FRONT FRONT Rotation Rotation FLYWHEEL END OF ENGINE ALL V-8 MODELS FIRING ORDER: FIRING ORDER: 1-8-4-3-6-5-7-2 1-2-7-5-6-3-4-8 Figure 11-1 V-8 Firing Orders TUNE-UP SPECIFICATIONS Model 5.7L (300 HP) Spark Plug Type P/N - R030010 Spark Plug Gap...

  • Page 59: Out-Of-Season Storage

    The fresh-water cooling system must be IMPORTANT: This service should be performed by serviced before fogging the engine for storage. an Authorized Crusader Dealer. CAUTION WARNING Refer to FLUSHING COOLING SYSTEM before Operate the bilge blower and be sure no fuel vapors proceeding.

  • Page 60: Draining Instructions

    OUT-OF-SEASON STORAGE - 12 DRAINING INSTRUCTIONS 4. Remove the raw water pump impeller. (See ENGINE MAINTENANCE) If inspection proves the impeller to be in good condition, store it in CAUTION an accessible spot for re-installation at the end of the storage period. A damaged or badly worn If the boat is to remain in the water during or after impeller should be discarded and a new one draining, close the seacock to prevent a siphoning...

  • Page 61: Out-Of-Season Engine Warm-Up

    If it is necessary to start your engine(s) during cold IMPORTANT: This service should be performed by weather storage, refer to the following procedure. an Authorized Crusader Marine Engines Dealer. 1. Refer to “Recommissioning After Storage” to When recommissioning the engine after storage, the...
  • Page 62 OUT-OF-SEASON STORAGE - 12 RECOMMISSIONING AFTER STORAGE CAUTION Failure to remove the excess storage oil from the engine’s cylinders can cause hydrostatic locking to occur, and severe damage to the engine. 8. Open the fuel shut-off valve (if equipped). 9. Refer to the OPERATING INSTRUCTIONS section and perform all the safety checks before starting the engine.

  • Page 63: Troubleshooting

    TROUBLESHOOTING - 13 Engine performance complaints usually fall under one of the basic headings listed in the Troubleshooting Guide. When a problem cannot be easily diagnosed, consult a Crusader Marine Engines Servicing Dealer for assistance. Malfunction Possible Cause Corrective Action...
  • Page 64 TROUBLESHOOTING - 13 Malfunction Possible Cause Corrective Action Engine Overheats Loose or worn drive belt(s) Adjust or replace the belts as necessary. Collapsed, kinked or leaking Replace the hoses. hoses. Transmission/engine oil cooler Remove the water hoses and fl ush plugged in opposite direction of the normal fl...
  • Page 65 Plugged fuel fi lters Replace the fuel fi lters. Faulty fuel pump. Have fuel pump replaced by a Crusader Marine Engines Dealer Plugged or kinked fuel lines or Repair or replace the fuel lines. fuel tank vent Remove obstruction.

  • Page 66: Troubleshooting

    TROUBLESHOOTING - 13 Malfunction Possible Cause Corrective Action Poor engine or boat Ignition malfunction Service ignition system. Check tune-up performance specifi cations. Carburetor malfunction Service carburetor. Throttle not fully open Check the remote control and carburetor linkage for freedom of movement and proper adjustment. Damaged or improper propeller Repair or replace as necessary.

  • Page 67: Water Flow Diagram

    WATER FLOW DIAGRAMS - 14 Figure 14-1 Fresh-Water Cooling System (5.7L) L510019-05...

  • Page 68: Engine Harness Wiring Diagrams

    ENGINE HARNESS WIRING DIAGRAMS - 15 ENGINE HARNESS WIRE HARNESS COLOR CHART ADAPTER CIRCUIT CIRCUIT ENGINE HARNESS NUMBER NAME WIRE COLOR GROUND BLACK TACHOMETER GRAY WATER TEMPERATURE IGNITION PURPLE BATTERY STARTER YELLOW/RED OIL PRESSURE LT. BLUE NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY. NOTE A : POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM THIS LOCATION.

  • Page 69: Engine Harness Wiring Diagrams

    ENGINE HARNESS WIRING DIAGRAMS - 15 10-P IN E NG INE BLACK 6 ga HAR NE S S RED/WHITE 16 ga ALT E R NAT OR PURPLE/WHITE 16 ga FROM PIN 5 6 ga Water T emp 14ga WAT E R T E MP S E NS OR B attery...

  • Page 70: Literature

    LITERATURE - 16 To obtain service and/or parts literature for your Crusader Marine Engines, contact the following: Crusader Marine Engines Publications Department P.O. Box 369 Little Mountain, SC 29075 IMPORTANT: When contacting the factory for service information, be sure to include your engine model and serial number to insure the service information you receive is correct.

  • Page 71: Forms

    CRUSADER OWNERSHIP CHANGE NOTICE If you are the new owner of a Crusader Marine Engine on which the warranty has expired and would like to inform Crusader of your ownership for notifi cation purposes in case of Service Updates, Recalls, etc., complete the section below and return by mail to Crusader Marine Engines, PO Drawer 369, Little Mountain, SC 29075.
  • Page 73 (PORT OR SINGLE ENGINE) The remainder of the original Crusader limited warranty is transferable within thirty (30) days of date of sale by the original owner/user to a subsequent purchaser for the remainder of the unused portion of the original warranty term, provided the engine(s) operating hours do not exceed 300. The original date of sale or original in-service date (whichever comes fi...
  • Page 75 (STARBOARD ENGINE) The remainder of the original Crusader limited warranty is transferable within thirty (30) days of date of sale by the original owner/user to a subsequent purchaser for the remainder of the unused portion of the original warranty term, provided the engine(s) operating hours do not exceed 300. The original date of sale or original in-service date (whichever comes fi...

  • Page 77: Notes

    NOTES - 18 L510019-05...
  • Page 78 Pleasurecraft Engine Group 1737 Highway 76 East, Little Mountain SC 29075...

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