CONTENTS 4 CYLINDER. ENGINE MECHANICAL GM V6 AND va ENGINES SPECIFICATIONS 4-41 ENGINE MECHANICAL. FORD va ENGINES SPECIFICATIONS 5-23 ENGINE OVERHAUL

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CONTENTS HOW TO USE THIS MANUAL 1 2 BOATING SAFElY 1-4 SAFETY IN SERVICE 1 11 TROUBLESHOOTING 1 11 TOOLS AND EQUIPMENT 1-15 TOOLS 1-17 FASTENERS, MEASUREMENTS AND CONVERSIONS 1-24 1-25 ENGINE AND

1 CONTENTS HOW TO USE THIS MANUAL 1 2 BOATING SAFElY 1-4 SAFETY IN SERVICE 1 11 TROUBLESHOOTING 1 11 TOOLS AND EQUIPMENT 1-15 TOOLS 1-17 FASTENERS, MEASUREMENTS AND CONVERSIONS ENGINE AND DRIVE MAINTENANCE 2 2 FLUIDS AND LUBRICANTS 2-33 LUBRICATION POINTS 2-47 BOAT MAINTENANCE 2-49 WINTER STORAGE 2-53 FIRING ORDERS 2-54 SPRING COMMISSIONING ENGINE MECHANICAL 4 CYLINDER ENGINE MECHANICAL 3-2 EXPLODED VIEWS ENGINE ENGINE MECHANICAL GM V6 AND va ENGINES 4-41 ENGINE MECHANICAL 4-2 EXPLODED VIEWS 4-36 ENGINE MECHANICAL 5-2 ENGINE MECHANICAL EXPLODED VIEWS 5-21 FORD va ENGINES 5-23 ENGINE OVERHAUL RECONDITIONING 6-2 FUEL AND COMBUSTION 7-2 CARBURETED FUEL SYSTEM 7-3 ROCHESTER 2-GE AND NIKKI2BBL 7-6 ROCHESTER 4ME 4BBL 7 10 HOLLEY BBL 7-16 HOLLEY BBL 7 20 HOLLEY BBL 7 25 HOLLEY 4150/4160/4175 4BBL 7-32 WIRING DIAGRAMS 7-44 SPECIFICAJIONS 7-46 FUEL AND COMBUSTION 8-2 FORD ELECTRONIC MULTI-POINT FUEL INJECTION (MFI) 8-3 GM THROTTLE BODY FUEL INJECTION (TBI) 8-20 GM MULTI-POINT FUEL INJECTION (MFI) 8-20 WIRING SCHEMATICS 8-62 ECM PIN LOCATIONS 8-74 DIAGNOSTIC TROUBLE CODE (DTC) CHARTS 8-79 FUEL FLOW DIAGRAMS 8-81 COMPONENT LOCATIONS 8-84 TORQUE 8-87

COOLING SYSTEMS MAINTENANCE AND TESTING FLOW DIAGRAMS 9-2 9-3 9-8 COOLING SYSTEM CONTENTS 9 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS CHARGING SYSTEM STARTER CIRCUIT IGNITION SYSTEM

2 COOLING SYSTEMS MAINTENANCE AND TESTING FLOW DIAGRAMS COOLING SYSTEM CONTENTS 9 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS CHARGING SYSTEM STARTER CIRCUIT IGNITION SYSTEM BREAKER POINT IGNITION SYSTEM DISTRIBUTOR IGNITION (01) SYSTEM ELECTRONIC SPARK TIMING (EST) SYSTEM BREAKERLESS INDUCTIVE DISTRIBUTOR (BID) VOLVO ELECTRONIC ENGINE MANAGEMENT (EMM) SYSTEM FORD THICK FILM INTEGRATED IGNITION SYSTEM rrfi-iv) DISTRIBUTORLESS ELECTRONIC IGNITION (EI) SYSTEM INSTRUMENTS AND GAUGES SENDING UNITS AND SWITCHES WIRING DIAGRAMS D D-38 1D-45 1Q..49 1D-5O 1Q..54 1().66 1() & STERN DRIVE UNIT-280f290. Sp. DP & DPX UPPER GEAR HOUSING INTERMEDIATE HOUSING. GEAR HOUSING (LOWER UNIT) TRANSOM SHIELD STERN DRIVE UNIT-8X & DP-S UPPER GEAR HOUSING LOWER GEAR CASE (LOWER UNIT) TRANSOM ASSEMBLY PJX WATERJET 13-2 JET DRIVE 13 ELECTRO-MECHANICAL TILT SYSTEM-280 & DP POWER TRIM ANDTILT-290. Sp. DP & DPX 14-5 TRIM AND TILT 1 POWER TRIM AND TILT-8X AND DP-S WIRING SCHEMATICS MANUAL STEERING SYSTEM POWER STEERING SYSTEM 15-3 STEERING SYSTEM MASTER INDEX MASTER INDEX

3 15-14 MASTER INDEX ALTERNATOR ASSEMBLY CHARGING SYSTEM INSPECTION... 1(}'11 CLEANING & INSPECTION DISASSEMBLY PRECAUTIONS... 1(}'11 REMOVAL &INSTALLATION... 1(}'15 TESTING ANODES (ZINCS) BACKLASH AND SHIM ADJUSTMENTS , SP, DP & DPX SXlDP-S BALANCE SHAFT BASIC OPERATING PRINCIPLES BATIERY CABLES CABLES CHARGERS CHARGERS... 1(}'10 CLEANING CONSTRUCTION location MARINE PRECAUTIONS RATINGS SPECIFIC GRAVITY STORAGE TERMINALS BELTS BOAT MAINTENANCE ANODES (ZINCS) BATIERIES INSIDE THE BOAT THE BOAT'S EXTERIOR BOATING SAFETY COURTESY MARINE EXAMINATIONS... ~ EQUIPMENT NOT REQUIRED BUT RECOMMENDED REGULATIONS FOR YOUR BOAT REQUIRED SAFETY EQUIPMENT BOWL BEARING BREAKER POINT IGNITION SYSTEM DESCRIPTION... 1(}'31 DISTRIBUTOR DISTRIBUTOR CAP AND ROTOR IGNITION COil... 1(}'37 TROUBLESHOOTING... 1(}'31 BREAKERLESS INDUCTIVE DISTRIBUTOR (BID) DESCRIPTION DISTRIBUTOR DISTRIBUTOR CAP IGNITION COil TROUBLESHOOTING CAMSHAFT FORD V GM V6fV CAMSHAFT, BEARINGS AND GEAR-4 CYl CARBURETED FUEL SYSTEM DECELERATION VALVE ELECTRIC FUEL PUMP HOllEY BBl HOllEY BBl HOllEY / BBl MECHANICAL FUEL PUMP OPERATION ROCHESTER 2-GE AND NIKKI2BBl ROCHESTER 4ME 4 BBl TROUBLESHOOTING CHARGING SYSTEM GENERAL INFORMATION GENERAL SYSTEM TROUBLESHOOTING... 1(}'11 ALTERNATOR CHEMICALS COMBINATION MANIFOLD COMPONENT LOCATIONS COOLANT FLOW DIAGRAMS COOLING SYSTEMS. ~2 DESCRIPTION &OPERATION DRAINING & FILLING FLOW DIAGRAMS FLUSHING MAINTENANCE AND TESTING TROUBLESHOOTING CYLINDER COMPRESSION CYLINDER HEAD 4 CYLINDER FORD V GM V6fV CYLINDER HEAD (VALVE) COVER I 4 CYLINDER FORDV GM V6fV DECELERATION VALVE DIAGNOSTIC TROUBLE CODE (DTC) CHARTS 8-79 DISTRIBUTOR AIR GAP DISTRIBUTOR IGNITION (01) SYSTEM DESCRIPTION DISTRIBUTOR DISTRIBUTOR CAP IGNITION COil TROUBLESHOOTING DISTRIBUTORLESS ELECTRONIC IGNITION (EI) SYSTEM 1().54 CAMSHAFT POSITION SENSOR...n... 1(}'55 CRANKSHAFT POSITION SENSOR DESCRIPTION & OPERATION IGNITION COilS ECM PIN LOCATIONS ELECTRIC FUEL PUMP ELECTRONIC SPARK TIMING (EST) SYSTEM DESCRIPTION DISTRIBUTOR DISTRIBUTOR CAP IGNITION COil TROUBLESHOOTING... 1(}'38 ELECTRONIC TOOLS ELECTRO-MECHANICAL TILT SYSTEM-280 AND DP DESCRIPTION TilT MECHANISM TROUBLESHOOTING ENGINE 4 CYLINDER FORDV GMV6N ENGINE AND DRIVE MAINTENANCE BELTS BREAKER POINTS AND CONDENSER CYLINDER COMPRESSION DISTRIBUTOR AIR GAP FLAME ARRESTOR FUEL FILTER IDLE SPEED AND MIXTURE IGNITION TIMING.j OVERVIEW PCV VALVE SERIAL NUMBER IDENTIFICATION SPARK PLUGS SPARK PLUG WIRES THERMOSTAT VALVE ADJUSTMENT ENGINE CIRCULATING PUMP FORD V GM V6fV ENGINE COUPLER AND FLYWHEEL-4 CYl ENGINE COUPlER/DAMPER-GM V6fV ENGINE COUPLER/DAMPER AND FLYWHEEL-FORD V ENGINE IDENTIFICATION 4 CYLINDER FORDV GM V6fV

MASTER INDEX 15-15 ENGINE MECHANICAL-4 CYL 3-2 CAMSHAFT, BEARINGS AND GEAR... 3-13 COMBINATION MANIFOLD... 3-7 CYLINDER HEAD... 3-15 CYLINDER HEAD (VALVE) COVER... 3-6 ENGINE.

4 MASTER INDEX ENGINE MECHANICAL-4 CYL 3-2 CAMSHAFT, BEARINGS AND GEAR COMBINATION MANIFOLD CYLINDER HEAD CYLINDER HEAD (VALVE) COVER ENGINE ENGINE COUPLER AND FLYWHEEL ENGINE IDENTIFICATION EXHAUST ELBOW EXHAUST HOSE (BELLOWS) EXHAUST PIPE FRONT COVER AND OIL SEAL FRONT ENGINE MOUNTS GENERAL INFORMATION HARMONIC BALANCER, PULLEY AND HUB HYDRAULIC VALVE LIFTER OIL FILTER BYPASS VALVE...'" OIL PAN OIL PUMP REAR ENGINE MOUNTS REAR MAIN OIL SEAL REAR MAIN OIL SEAL RETAINER ROCKER ARMS AND PUSH RODS ENGINE MECHANICAL-FORD V CAMSHAFT CYLINDER HEAD CYLINDER HEAD (VALVE) COVER ENGINE ENGINE CIRCULATING PUMP ENGINE COUPLER/DAMPER AND FLYWHEEL ENGINE IDENTIFICATION EXHAUST ELBOW EXHAUST HOSES (BELLOWS) EXHAUST MANIFOLD FLYWHEEL FRONT COVER AND OIL SEAL FRONT ENGINE MOUNTS GENERAL INFORMATION HYDRAULIC VALVE LIFTER INTAKE MANIFOLD... 5-S INTERMEDIATE EXHAUST PIPE LOWER EXHAUST PIPE (Y-PIPE) OIL PAN OIL PUMP REAR ENGINE MOUNTS REAR MAIN OIL SEAL ROCKER ARMS AND PUSH RODS TIMING CHAIN AND SPROCKETS S VIBRATION DAMPER, PULLEY AND HUB WATER PUMP ENGINE MECHANICAL-GM V61V BALANCE SHAFT CAMSHAFT CYLINDER HEAD CYLINDER HEAD (VALVE) COVER... 4-S ENGINE ENGINE CIRCULATING PUMP ENGINE COUPLERIDAMPER ENGINE IDENTIFICATION EXHAUST ELBOW EXHAUST HOSES (BELLOWS) EXHAUST MANIFOLD FLYWHEEL FRONT COVER AND OIL SEAL FRONT ENGINE MOUNTS GENERAL INFORMATION HARMONIC BALANCER, PULLEY AND HUB S HYDRAULIC VALVE LIFTER INTAKE MANIFOLD INTERMEDIATE EXHAUST PIPE LOWER EXHAUST PIPE (Y-PIPE) OIL FILTER BYPASS VALVE OIL PAN OIL PUMP REAR ENGINE MOUNTS REAR MAIN OIL SEAL REAR MAIN OIL SEAL RETAINER ROCKER ARMS AND PUSH RODS TIMING CHAIN AND SPROCKETS WATER PUMP..., ENGINE RECONDITIONING DETERMINING ENGINE CONDITION BUY OR REBUILD? ENGINE OVERHAUL TIPS ENGINE PREPARATION CYLINDER HEAD..., ENGINE BLOCK ENGINE START UP AND BREAK IN EXHAUST ELBOW 4CYLINDER FORDVS GMV6NS EXHAUST HOSE (BELLOWS) 4CYLINDER FORDVS GMV6NS EXHAUST MANIFOLD FORDVS GMV6NS EXHAUST PIPE EXHAUST VALVE (FLAPPER) REPLACEMENT EXPLODED VIEWS-4 CYL CYLINDER BLOCK CYLINDER HEAD FLYWHEEL HOUSING AND REAR MOUNTS EXPLODED VIEWS-FORD V CYLINDER BLOCK CYLINDER HEAD INTAKE MANIFOLD..., EXPLODED VIEWs-GM V6IV CYLINDER BLOCK - V CYLINDER BLOCK-VS CYLINDER HEAD-V CYLINDER HEAD-5.0U5.7L V CYLINDER HEAD-7.4U8.2L V INTAKE MANIFOLD-V6 ENGINES, 5.0U5.7L VS AND U8.2L GL VS LOWER INTAKE MANIFOLD U8.2L GIIGSI V8 AND US.1US.2L GSI V LOWER INTAKE MANIFOLD US.1 U8.2L GI V UPPER INTAKE MANIFOLD U8.2L GIIGSI VS AND US.1U8.2L GSI VS UPPER INTAKE MANIFOLD US.1U8.2L GI V FASTENERS, MEASUREMENTS AND CONVERSIONS BOLTS, NUTS AND OTHER THREADED RETAINERS STANDARD AND METRIC MEASUREMENTS TORQUE FIRING ORDERS FLAME ARRESTOR FLUIDS AND LUBRICANTS COOLING SYSTEM ENGINE FLUID DISPOSAL FUEL AND OIL RECOMMENDATIONS POWER STEERING POWER TRIM PUMP STERN DRIVE UNIT FLYWHEEL FORDV GMV6N FORD ELECTRONIC MULTI POINT FUEL INJECTION (MFI) 8-3 AIR CHARGE TEMPERATURE SENSOR (ACn CIRCUIT BREAKER DESCRIPTION AND OPERATION DIAGNOSTIC TROUBLE CODES-EEC IV SYSTEM EEC POWER RELAY

15-16 MASTER INDEX ELECTRONIC CONTROL ASSEMBLY (ECA)... 8-9 ENGINE COOLANT TEMPERATURE SENSOR (ECl)... 8-8 FUEL INJECTOR... 8-9 FUEL PRESSURE REGULATOR... 8-9 FUEL PUMP................................ 8-10 FUEL RAIL.

5 15-16 MASTER INDEX ELECTRONIC CONTROL ASSEMBLY (ECA) ENGINE COOLANT TEMPERATURE SENSOR (ECl) FUEL INJECTOR FUEL PRESSURE REGULATOR FUEL PUMP FUEL RAIL FUEL RESERVOIRNAPOR SEPARATOR IDLE SPEED CONTROL (ISC) SOLENOID KNOCK SENSOR (KS) AND AMPLIFIER MAP SENSOR PIN LOCATIONS RELIEVING FUEL PRESSURE SYSTEM DIAGNOSIS THROTILE BODY THROTILE POSITION SENSOR (TP) VACUUM DIAGRAMS FORDTHICK FilM INTEGRATED IGNITION SYSTEM (TFI IV) DESCRIPTION & OPERATION... H)-50 DISTRIBUTOR DISTRIBUTOR CAP E-CORE COIL STATOR FI MODULE FRONT COVER AND OIL SEAL 4 CYLINDER FORD V GM V6N FRONT ENGINE MOUNTS 4 CYLINDER FORDV GMV6N FUEL AND COMBUSTION FUEL AND OIL RECOMMENDATIONS FUEL FILTER FUEL FLOW DIAGRAMS FUEL PUMP ELECTRIC MECHANICAL GEAR HOUSING (lower UNIT)-28OI29O, SP, DP & DPX DESCRiPTION INTERMEDIATE HOUSING TO LOWER UNIT SHIMMING PROPELLER PROPELLER ROTATION CHANGE REMOVAL & INSTALLATION RETAINING PAWL ADJUSTMENT GIMBAL HOUSING GIMBAL RING GM THROTIlE BODY FUEL INJECTION (TBI) & GM MULTI-POINT FUEL INJECTION (M"FI) 8-20 CIRCUIT BREAKER CLEARING CODES DESCRIPTION AND OPERATION DIAGNOSTIC TEST SCHEMATICS (GM) DIAGNOSTIC TROUBLE CODES (DTC) DIAGNOSTIC TROUBLE CODE SCHEMATICS ELECTRONIC CONTROL MODULE (ECM) ENGINE COOLANT TEMPERATURE SENSOR (ECl) FUEL CELL FUEL INJECTORS FUEL LINE QUICK-CONNECT FITIINGS FUEL METER BODY FUEL METER COVER FUEL PRESSURE REGULATOR FUEL PUMP FUEL PUMP RELAY FUEL RAIL GENERAL DIAGNOSTIC TESTS IDLE AIR CONTROL VALVE (lac) INTAKE AIR TEMPERATURE SENSOR (IAl) KNOCK SENSOR (KS) KNOCK SENSOR MODULE MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) READING CODES RELIEVING FUEL PRESSURE SYSTEM DIAGNOSIS THROTILE BODY THROTILE BODY ADAPTER PLATE THROTILE POSITION SENSOR (TP) VAPOR SEPARATORTANKIFUEL RESERVOIR HAND TOOLS HARMONIC BALANCER, PULLEY AND HUB 4 CYLINDER GM V6N HOllEY BBl ASSEMBLY CLEANING & INSPECTION DISASSEMBLY REMOVAL & INSTALLATION HOllEY BBl 7-20 ADJUSTMENT ASSEMBLY CLEANING & INSPECTION DiSASSEMBLy REMOVAL & INSTALLATION HOllEY BBl REMOVAL & INSTALLATION DiSASSEMBLy CLEANING & INSPECTION ASSEMBLY ADJUSTMENT HOllEY BBl REMOVAL & INSTALLATION DISASSEMBLY CLEANING & INSPECTION ASSEMBLY ADJUSTMENT HOW TO USETHIS MANUAL. 1-2 AVOIDING THE MOST COMMON MISTAKES AVOIDING TROUBLE CAN YOU DO IT? DIRECTIONS AND LOCATIONS MAINTENANCE OR REPAIR? PROFESSIONAL HELP PURCHASING PARTS WHERE TO BEGIN HYDRAULIC VALVE LIFTER 4 CYLINDER FORDV GMV6N IDLE SPEED AND MIXTURE IGNITION SYSTEM APPLICATIONS IGNITION TIMING INSTRUMENTS AND GAUGES BATIERY GAUGE FUEL GAUGE OIL AND TEMPERATURE GAUGES SPEEDOMETER TACHOMETER INTAKE MANIFOLD FORDV GM V6N INTERMEDIATE EXHAUST PIPE FORD V GM VaN LOWER EXHAUST PIPE (Y PIPE) FORD V GM VaN INTERMEDIATE HOUSING DESCRIPTION INTERMEDIATE HOUSING TO LOWER UNIT SHIMMING REMOVAL & INSTALLATION...' lower GEAR CASE (lower UNIT)-SXlDP-S DESCRIPTION PROPELLER REMOVAL & INSTALLATION lubrication points

MASTER INDEX 15-17 GIMBAL BEARING AND U..JOINTS... 2-48 PROPELLER SHAFT...,... 2-47 SHIFT CABLE AND TRANSMISSION LINKAGE PIVOT POINTS... 2-48 STEERING SYSTEM... 2-48 THROTTLE CABLE.

6 MASTER INDEX GIMBAL BEARING AND U..JOINTS PROPELLER SHAFT..., SHIFT CABLE AND TRANSMISSION LINKAGE PIVOT POINTS STEERING SYSTEM THROTTLE CABLE MANUAL STEERING SYSTEM STEERING CABLE STEERING TUBE TRIM TAB MEASURING TOOLS MECHANICAL FUEL PUMP OIL FILTER BYPASS VALVE 4 CYLINDER GM VaNB OIL PAN 4 CYLINDER FORDVB GM VaNB OIL PUMP 4 CYLINDER FORD VB GM VaNB PCV VALVE PIVOT HOUSING PJX WATERJET BOWL BEARING REVERSE GATE STEERING NOZZLE... ".:;. : THRUST BEARING AND SEAL HOUSING WEAR RING POWER STEERING BLEEDING FLUID LEVEL POWER STEERING COOLER POWER STEERING CYLINDER POWER STEERING PUMP POWER STEERING SySTEM DESCRIPTION MAINTENANCE PROCEDURES POWER STEERING COOLER POWER STEERING PUMP STEERING CABLE STEERING CYLINDER B TESTING TRIM TAB POWER TRIM AND TILT-290, SP, DP AND DPX 14-5 DESCRiPTION HYDRAULIC TRIM PUMP TRIM CYLINDERS TRIM INDICATOR GAUGE SENDING UNIT TROUBLESHOOTING POWER TRIM ANDTlLT-8X AND DP S DESCRiPTION HYDRAULIC LINES & MANIFOLD SYSTEM BLEEDING SERVICE PRECAUTIONS SYSTEM TESTING TRIM LIMITER TRIM SENDER TRIMfTILT PUMP ASSEMBLY TROUBLESHOOTING TRIMfflLT CYLINDER PROPELLER SP MODELS DP MODELS DP S MODELS DPX MODELS RETAINING PAWL ADJUSTMENT ROTATION CHANGE SX MODELS RAW WATER PUMP REAR ENGINE MOUNTS 4 CYLINDER FORDVB GMVaNB REAR MAIN OIL SEAL 4 CYLINDER FORD VB GM VaNB REAR MAIN OIL SEAL RETAINER 4 CYLINDER GM VaNB REGULATIONS FOR YOUR BOAT REQUIRED SAFETY EQUIPMENT REVERSE GATE ROCHESTER 2-GE AND NIKKI2BBL. 7-6 ADJUSTMENT ASSEMBLY... 7 B CLEANING & INSPECTION DISASSEMBLY REMOVAL & INSTALLATION ROCHESTER 4ME 4 BBL ADJUSTMENT ASSEMBLY CLEANING & INSPECTION DESCRIPTION DISASSEMBLY REMOVAl & INSTALLATION ROCKER ARMS AND PUSH RODS 4 CYLINDER FORDVB GMV6NB SAFETY IN SERVICE SAFETY TOOLS SENDING UNITS AND SWITCHES 1().58 AUDIO WARNING SYSTEM ~59 IGNITION SWITCH OIL PRESSURE SENDING UNIT WATER TEMPERATURE SENDER SERIAL NUMBER IDENTIFICATION ENGINE STERN DRIVE TRANSOM ASSEMBLY SHIFT MECHANISM , SP, DP & DPX SXlDP S SPARK PLUGS SPARK PLUG WIRES SPECIAL TOOLS ALTERNATOR B CAPACITIES CARBURETOR APPLICATIONS CARBURETOR CONVERSION FACTORS DRIVE MODEL APPLICATIONS ENGINE MODEL APPLICATIONS ENGINE 4 CYLINDER FORD VB GM VaNB MAINTENANCE INTERVALS METRIC BOlTS SAE BOlTS TORQUE 4 CYLINDER B CARBURETOR EFI... B-87 FORD VB GM VaNB TROUBLESHOOTING TUNE UP SPRING COMMISSIONING STARTER CiRCUIT DESCRIPTION AND OPERATION TROUBLESHOOTING THE STARTING SYSTEM STARTER MOTOR

7 15-18 MASTER INDEX SOLENOID STARTER MOTOR DESCRIPTION &OPERATION DISASSEMBLY &ASSEMBLY PINION CLEARANCE PRECAUTIONS REMOVAL & INSTALLATION TROUBLESHOOTING STARTER SOLENOID STEERING CABLE STEERING FORKlHELMET STEERING TUBE STEERING NOZZLE STERN DRIVE UNIT FLUID LEVEL CHECKING FOR WATER DRAIN AND REFILL STERN DRIVE UNIT , SP, DP AND DPX 11-2 DESCRIPTION EXHAUST BELLOWS REMOVAL &INSTALLATION STERN DRIVE UNIT TROUBLESHOOTING U-JOINT BELLOWS STERN DRIVE UNIT-5X1DP-S DESCRiPTION REMOVAL & INSTALLATION TRIM SENDING UNIT ADJUSTMENT TROUBLESHOOTING THERMOSTAT REMOVAL & INSTALLATION TESTING THRUST BEARING AND SEAL HOUSING TIMING CHAIN AND SPROCKETS FORD V GM V6IV TOOLS ELECTRONIC TOOLS HAND TOOLS MEASURING TOOLS OTHER COMMON TOOLS SPECIAL TOOLS TOOLS AND EQUIPMENT 1 15 CHEMICALS SAFETY TOOLS TRIM TAB MANUAL POWER TRANSOM ASSEMBLY DESCRIPTION GIMBAL HOUSING GIMBAL RING PIVOT HOUSING REMOVAL &INSTALLATION SHIFT CABLE SLEEVE REPLACEMENT TRANSOM SHIELD DESCRIPTION STEERING FORKlHELMET TROUBLESHOOTING BASIC OPERATING PRINCIPLES U-JOINT BELLOWS , SP, DP & DPX SXlDP S U-JOINTIDRIVE SHAFT ASSEMBLY I , SP, DP & DPX SXlDP-S UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 10.2 BASIC ELECTRICAL THEORY ELECTRICAL COMPONENTS TEST EQUIPMENT WIRE AND CONNECTOR REPAIR UPPER GEAR HOUSING-28Ofl9O, SP, DP & DPX BACKLASH AND SHIM ADJUSTMENTS DESCRiPTION REMOVAL & INSTALLATION SHIFT MECHANISM U..JOINT BELLOWS U..JOINTIDRIVE SHAFT ASSEMBLY UPPER GEAR HOUSING-sXIDp S BACKLASH AND SHIM ADJUSTMENTS DESCRIPTION EXHAUST BELLOWS REMOVAL & INSTALLATION SHIFT MECHANISM U-JOINT BELLOWS U-JOINTIDRIVE SHAFT ASSEMBLY VALVE ADJUSTMENT VIBRATION DAMPER, PULLEY AND HUB \ VOLVO ELECTRONIC ENGINE MANAGEMENT (EMM) SYSTEM DESCRIPTION &OPERATION SYSTEM COMPONENTS WATER PUMP FORD GM V6IV WATER (ENGINE) CIRCULATING PUMP FORD ENGINES GM ENGINES WEAR RING WINTER STORAGE 2-53 WIRING DIAGRAMS CARBURETOR CHARGING SySTEM ENGINE FUEL INJECTION IGNITION SYSTEM STARTING SYSTEM TRIMfTILT

1 GENERAL INFORMATION,

CONTENTS 1 GENERAL INFORMATION, AND BOATING SAFETY HOW TO USE THIS MANUAL 1 2 BOATING SAFETY 1 3 SAFETY IN SERVICE 1-11 TOOLS AND EQUIPMENT 2-2 TOOLS 2-4 FASTENERS, MEASUREMENTS AND CONVERSIONS 2-12 ENGINE