TABLE OF CONTENTS 1 SAFETY CLEANING, WAXING, POLISHING CONTROLLING CORROSION Using Zinc PROPELLERS FUEL SYSTEM LOADING FLOTATION HORSEPOWER EMERGENCY EQUIPMENT COMPASS STEERING ANCHORS MISCELLANEOUS EQUIPMENT BOA TING ACCIDENT REPORTS NAVIGATION 2 TUNING TUNING FOR PERFORMANCE IGNITION FUEL SYSTEM 3 ENGINE GENERAL PRINCIPLES Valve Timing Engine Types Service Procedures Mechanical Engine Problems GMC IN-LINE ENGINES Exhaust Manifold Reconditioning Valve Lash Adjustment 1-2 1-2 1-8 0 1 1 3 5 9 9 2-1 2-1 2-5 2-8 3-1 3-6 3-8 3-8 3-9 3-10 3-10 3-11 3-11 3-18 3-19 3-20 Piston Ring and Rod Service Crankcase Front Cover GMC V6 ENGINES Main Bearings Rear Bearing Oil Seal Timing Chain Service GMC V8 ENGINES Prep. Valve Lash Adjustment 3-21 3-22 3..:24 3-27 3-28 3-29 1 2 3 7 8 8 9 9 3-44 3-46 3-55 3-56 3-57 3-62 3-63 3-64 3-65 3-65 3-71 3-71 3-72 3-73 3-80 3-80

GMC V8 ENGINES (Continued) Main Bearings Timing Chain FORD V8 ENGINES Checking Hydraulic Lifter Clearance Main Bear ings Timing Chain 4 FUEL Fuel Pump Fuel Line Rough Engine Idle Excessive Fuel Consumption Engine Surge SINGLE-DIAPHRAGM FUEL PUMP DUAL-DIAPHRAGM FUEL PUMP FUEL FILTER REPLACEMENT CARBURETORS Rochester BC Carburetor Adjusting Carter RBS Carburetor &. Operation Rochester 2GC D isassem bling 3-84 3-85 3-87 3-89 3-89 3-90 3-91 3-92 3-93 3-93 3-100 3-100 3-101 3-103 3-109 3-110 3-112 3-113 3-113 3-114 3-117 3-118 4-1 4-2 4-2 4-4 4-6 4-7 4-10 4-10 4-12 4-14 4-15 4-15 4-18 4-22 0 3 5 IGNITION Rochester 4MV Holley Adjustments Compression General Tests Primary Circuit Tests Contact Point Test Condenser Test Secondary Circuit Test Rotor Test Ignition Voltage Tests Spark Plug Polarity Check DISTRIBUTOR SERVICE SERVICING A DELCO-REMY - from a 4- or 6-cylinder in-line engine from a GMC V6 1964-72 or V8 Gapping Contact Points 5 5 9 4-41 4-45 4-50 4-50 4-55 4-58 4-61 5-1 5-3 5-3 5-4 5-4 5-5 5-5 5-9 5-12 5-12 5-14 5-1 1t 5-14 5-16 5-16 5-19 5-19 SER VICING A MALLOR Y 5-20 from All V6 and V8 engines 1981 and on 5-20 SER VICING AN AUTOLlTE OR PRESTOLITE ADJUSTING POINT GAP ALL DISTRIBUTOR INST ALLA TION Adjusting the Dwell Adjusting Timing Adjusting lcile Speed and Mixture 5-24 5-25 5-26 5-27 5-27 5-30

, ELECTRICAL BATTERIES JUMPER CABLES DUAL BATTERY INSTALLATION GAUGES AND HORNS Oil and Temperature Gauges Warning Lights Fuel Gauges Tachometer Horns CHARGING SYSTEM Alternator Servicing Charging System with Separate Regulator Servicing Charging System with Integral Regulator CRANKING SYSTEM DeJco-Remy Starter Servicing Testing Autollte Starter Disassem bung Bench Tests Prestolite Starter 7 ACCESSORIES SHIFT BOXES Single- and Side-Moun t Boxes &. Repair Push Button Shift Box &. Repair Binnacle-Mounted Shift Box &. Repair 6-1 6-1 6-5 6-6 6-8 6-10 6-10 6-11 6-11 6-12 6-13 6-16 6-18 6-21 6-21 6-25 6-25 6-26 6-26 6-30 6-31 6-32 6-32 6-33 6-35 6-38 7-4 7-4 7-5 7-5 7-6 7-7 SELECTRIM FOR FORD V8 ENGINES 9 &. Operation 9 &. 7-20 Cylinder 7-21 Cylinder 7-22 7-23 HYDRAULIC PUMP &. MOTOR 7-24 7-24 7-25 7-26 7-27 Replacing Manual Release Valve 7-27 Adding Fluid or Filling a Dry System 7-27 Electrical Checks 7-28 TRU-COURSE STEERING 7-28 &. Operation 7-28 7-29 7-30 Cable Drum-and-Bracket 7-31 7-31 7-32 Adjustments 7-33 MECHANICAL STEERING 7-34 Cable 7-35 Cable 7-36 OVER-UNDER STEERING HELM 7-37 7-37 Cable Replacement 7-37 Helm 7-38 FINAL CHECKS &. ADJUSTMENTS 7-40 8 Tn..T MECHANISM AND OPERATION 8-1 8-2 TILT MOTOR SERVICE 8-3 8-3 Testing 8-4 8-5 8-7 8-8 HAMMER BLOW COUPLING 8-9 TILT CLUTCH &: WORM GEAR 8-9 8-10 &: 8-1 I 9 COOLING THROTTLE CABLE INSTALLATION SELECTRIM FOR IN-LINE ENGINES &. Operation &. 7-8 7-9 7-9 0 5 8 EXHAUST MANIFOLDS THERMOSTAT REPLACEMENT WATER PUMP REMOVAL 9-1 9-6 9-11 9-12 9-12 9-15

10 STERN DRIVE EARL Y STERN DRIVE UNITS 1964-77 Upper Gear Housing Water Pump Ball Gear Bearing Housing Worm Gear Steering Disassembly Ball Gear Bear ing Housing Water Pump Exhaust Housing Swivel Housing Lower Unit & Swivel Housing Exhaust Housing Upper Gear Housing Stern Drive 10-1 10-1 10-3 10-4 10-7 10-8 10-9 10-10 10-11 10-14 10-15 10-18 10-19 10-21 10-22 10-28 10-37 10-38 10-41 10-44 & Forward Gear Propeller Shaft and Shifter Power Assist Servo D isassem bling Shift Cable or Replacement Pinion Bearing Shimming Pinion Bearing Race & Forward Gear Driveshaft & Pinion Gear Propeller Shaft, Assist Valve, & Plunger Exhaust Housing Upper Gear Housing Stern Drive 10-76 10-77 10-78 10-80 10-80 10-81 10-82 10-84 10-86 10-87 10-87 10-88 10-91 10-92 10-95 STERN DRIVE UNITS SINCE 1978 Shift Converter Service Cable Stern Drive Upper Gear Housing Water Pump Ball Gear D isassem bling Bearing Housing Worm Gear Steering D isassembllng Ball Gear Bearing Housing Water Pump Exhaust Housing Swivel Housing Swivel Housing Lower Unit & Propeller Shaft Driveshaft Bearing Housing 10-47 10-47 10-50 10-50 10-51 10-52 10-52 10-54 10-55 10-56 10-58 10-59 10-62 10-63 10-65 10-66 10-67 10-68 10-68 Shift Converter Cable Shift Adjustment Trim Tab Adjustment II INTERMEDIATE HOUSING SERVICING THE BOOT BALL GEAR DRIVESHAFT INTERMEDIATE HOUSING 12 MAINTENANCE FIBERGLASS HULLS BELOW WATERLINE SERVICE OFF-SEASON STORAGE PRE-SEASON PREPARATION 10-97 10-99 10-102 1 1 11-3 11-3 11-7 10 10 11 12-5

APPENDIX CONVERSIONS Metric Drill Size SPECIFICA TlONS Tune-Up Spark Advance Charts Carburetor Specifications GMC In-Line Engine Specs Kaiser V6 (GMC V6) Specs GMC 6-Cylln-Line Specs GMC V8 Specs GMC V6 Specs Ford V8 TORQUE VALUES GEAR RATIOS AND OIL CAPACITIES WIRE IDENTIFICATION Second station Instrument Cable Connector Stern Drive Instrument, Cable, and Switch 185 &: 225 hp SelecT rim 185 &: 225 hp Preset Trim 185 &: 225 hp SelecT rim Models "H" &: IIJII 185 &: 225 hp Preset Trim Models "H" &: "J" 185, 200, 230, &: 260 hp SelecTrim 185, 200, 230, &: 260 hp Preset Trim 120 &: 140 hp SelecTrim A-I A-2 A-3 A-I0 A-16 A-18 A-20 A-23 A-24 A-33 A-35 A-51 A-55 A-70 A-71 A-72 A-73 A-74 A-75 A-76 A-77 A-78 A-79 A-80 Mode I "HI! and "H I" 120 &: 140 hp SelecT rim Model "H" and "H 1" 175, 195, and 235 hp with fixed mount 175, 195, and 235 hp 240 hp SelecT rim Model "H" and "J" 240 hp Preset Trim 240 hp Preset Trim Model "H" and "J" 240 hp SelecT rim 250 hp SelecT rim 120 and 140 hp, also 2.5 and 3.0 Litre with fixed trim 120 and 140hp also 2.5 and 3.0 Litre 200, 230, 260 hp also 5.0 &: 5.7 Litre 185, 200, 230 and 260 hp also 5.0 &: 5.7 Litre Tilt System 185, 200, 230 and 260 hp Tilt System 120 and 140 hp Tilt System 3.8, 4.3, 5.0 and 5.7 Litre Tilt System 2.5 &: 3.0 Litre Trim System 5.0 &: 5.7 Litre Ignition System 2.5, 3.0 3.8 and 4.3 Litre Trim System 2.5 &: 3.0 Litre Trim System 3.8, 4.3, 5.0 and 5.7 Litre A-81 A-82 A-83 A-84 A-85 A-86 A-87 A-88 A-89 A-90 A-91 A-92 A-93 A-94 A-94 A-95 A-95 A-96 A-96 A-97 A-97